Total Technical Specs PDF

Technical Specification of 259

MPMKVVCL/FSP-II/ADB/F-03 / Vol.II Single Stage Two Envelope

TECHNICAL SPECIFICATIONS

Part A General: 1.1 It is not the intent to specify herein complete details of design and construction of the

plant/equipment/material. The plant offered shall conform to the relevant standards and shall be of high quality, sturdy, robust and of good design and workmanship complete in all respects and capable to perform continuous and satisfactory operations in the actual service conditions at site and shall have sufficiently long life in service. The dimensional drawings attached with the Technical Specification in Volume II are generally of illustrative nature. In actual practice, not withstanding any anomalies, discrepancies, omissions, incompleteness, etc. in these specifications and attached drawings, the design and constructional aspects, including materials and dimensions, will be subject to good engineering practice in conformity with the required quality of the product and to such tolerances, allowances and requirements for clearances etc. as are necessary by virtue of various stipulation in that respect in the relevant Indian Standards, IEC standards, I.E. Rules and other statutory provisions.

1.2 The plant/equipment/material offered shall be complete with all parts necessary for their effective

and trouble free operation. Such parts will be deemed to be within the scope irrespective of whether they are specifically indicated in the Bid documents or not.

Quality Assurance Programme: 1.3 Bidder must establish that a proper quality assurance program is being followed by them for

manufacture of plant/equipment. Quality Assurance Program must have a structure as detailed in following paragraphs.

a) Quality assurance and failure prevention starts with careful study and scrutiny of our technical

specifications and requirements. Bidder/manufacturer shall carefully study all the technical parameters and other particulars and the Bidder/manufacturer shall categorically give his confirmation that these requirements shall be met in a satisfactory manner.

b) Bidder/manufacturer shall furnish the checks exercised in design calculations. The salient

features of design shall be made available to the Employer.

c) Bidder/manufacturer shall indicate the various sources of the items being procured. Type of checks, quantum of checks and acceptance norms shall be intimated and random test and check results should be made available for inspection whenever so desired.

d) The Bidders shall invariably furnish following information.

1. Statement giving list of important raw materials, names if sub-Bidder/manufacturers for the raw material, list of standards according to which the raw material is purchased and copies of test certificates thereof.

2. Information and copies of test certificates as in (i) above in respect of bought out items.

3. List of machines and manufacturing facilities available.

4. Levels of automation achieved and list of areas where manual processing exists.

5. List of areas in manufacturing process, where stage inspections are normally carried out for

quality control and details of such tests and inspections.

6. List of testing equipment available with the Bidder for final testing of materials specified and test plant limitation, if any, vis-à-vis type, special, acceptance and routine tests specified in the relevant standards. These limitations shall be very clearly brought out in schedule of deviations from specified test equipments.

Pre Dispatch Inspection: 1.4 The Employer’s representative may carry out stage inspection of the plant/equipment during manufacturing/ assembling stage. The Employer shall have absolute right to reject the raw material/ component/ sub assemblies or complete equipment not found to be conforming to the specification or being of poor quality/ workmanship. The stage inspection will particularly include tests specified for any



particular plant or equipment in the technical specification, general routine tests and physical measurements to be conducted during manufacturing stages as per manufacturer’s standard practice. 1.5 The Bidder/manufacturer shall give fifteen (15) days advance notice to enable the Employer to arrange for inspection. Inspection and testing shall be conducted at the place of manufacture. Inspection and testing of any material under this specification by the Employer shall not relieve the Bidder/manufacturer of his obligation to supply the plant/equipment in accordance with the specification and shall not prevent subsequent rejection if it is found to be defective. 1.6 The Bidder/manufacturer shall afford the Employer’s representative all reasonable facilities, without charge, to satisfy him that the plant/ equipment is being manufactured in accordance with the specifications. The Bidders/manufacturer must have adequate set of instruments for conducting tests as per ISS specification. Instruments shall be duly calibrated and calibration certificate should not be older than one year on the date of inspection. Calibration shall be done by NABL accredited laboratories. A comprehensive list of testing equipment/ instruments indicating make, Sr.No., type, class of accuracy, calibrating agency, calibration date etc. should be furnished, as and when desired. Calibrated instruments shall be duly sealed by calibrating agency to avoid any tampering with calibration and the details thereof shall be clearly mentioned in the calibration certificate(s).

Defect Liability:

1.7 The defect liability period of plants/ equipments shall be as indicated in GCC 27 of Sec 7 and GCC 27.10 of Sec 8 of the bid document Vol. I. Type Test:

1.8 The type test certificates for all the items shall be required to be submitted within twenty eight (28) days of the date of Notifiction of Award to the successful bidder. Failure to submit the type tests shall constitute sufficient grounds for the annulment of contract as per sub-clause 40.2 of Section 1.

The type test of any item shall not be more than three (3) years old from the date of submission of Bid. The Employer may get the Type test or routine tests of any equipment done at Accredited Laboratory by NABL in the country. The type test may be done even after receipt of materials at Contractor’s site store but not after the guarantee period for the equipment as described elsewhere. The results of such tests will be decided on pass fail basis. In case the equipment fails to pass the Type test, the cost of such test shall be borne by the Contractor. 1.9 The Bidder/manufacturing programme shall not be interrupted merely because the plant/equipment has been offered for inspection. 1.10 Specification for individual plant /equipment is subject to the conditions mentioned above.



PART B 1.0 TECHNICAL SPECIFICATION OF THREE PHASE 11/0.4 33 KV, 25 KVA RATING OUTDOOR TYPE COMPLETELY SELF PROTECTED DISTRIBUTION TRANSFORMERS. 1.1 SCOPE:

Specification covers the design, engineering, manufacture, assembly, stage testing, inspection and testing at manufacturer’s works before supply and delivery at site of Oil immersed, Oil Natural Air Natural (ONAN) outdoor type 11KV/433 V, three phase, 50 Hz, double wound core type, outdoor type EC grade aluminum wound Distribution Transformer of 25 KVA ratings, complete with fittings and accessories for metering and protection unit on LT side of Distribution Transformer for use in Distribution System.

1.1.2 Tolerances on all the dimensions shall be in accordance with provisions made in the relevant Indian/ IEC standards and in these specifications. Otherwise the same will be governed by good engineering practice in conformity with required quality of the product.

1.2 APPLICABLE STANDARDS: Unless otherwise modified in the specifications, the distribution transformers, including various accessories, shall generally comply with the following Indian Standards / REC Specifications. The standard(s) shall be with latest amendment, if any. Note: Wherever ISS are mentioned, equivalent or better International standards are also acceptable.

Sr. No.

Specification Details about

1 IS: 1180 (PART-I)

Specifications for outdoor type three phase distribution transformers up to and including 100 KVA, 11 KV Class.

2 IS:6600-1978 Guide for loading of oil immersed Transformers

3 IS:335-1983 New insulation oils for Transformers

4 IS:3347 (Part-I Sec. 1 & 2)

Dimension of Porcelain parts & Metal parts for Transformer bushing (1.1 KV)- for LT

5 IS:3347 (PART-III / Sec-1 & 2) Dimensions of Porcelain parts & Metal parts for Transformer bushing (17.5 KV)- for 11 kV

6 IS:7421 Porcelain Transformer Bushings for low voltage – up to 1 KV.

7 IS:2099-1986

Porcelain Transformer bushing for AC volts above 1000 volts.

8 IS:3639-1966

Fittings & accessories for Transformers

9 IS:1866-1978 Code of practice for maintenance & supervision of insulating oil in service.

10 IS:5484

Specifications for Aluminum wire rods.

11 IS:9335

Specifications for insulating kraft paper.

12 IS:1576

Specifications for solid insulating press Boards for electrical purposes.

13 IS:616 (Part I)

Specification for paper covered Aluminum round conductors

14 IS:6162(Part II)

Specification for paper covered Aluminum rectangular conductors

15 IS:104

Ready mixed paint, brushing zinc chromate, painting

16 IS:649 Testing of steel sheets and strips for magnetic circuits.



17 IS:2362

Determination of water content in oil for transformers.

18 IS: 4257 Dimensions for clamping arrangements for bushings.

19 IS 6160

Rectangular conductor for electrical machines.

20 IS:10028

Selection, Installation and maintenance of transformers

21 IS:3401 Silica gel 22 - REC Specification No. 2

- REC Specification No. 39/1993 - CEA Specification Chapter 4

Materials conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. 1.3 SERVICE CONDITIONS:

The distribution transformers to be supplied against this specification shall be suitable for satisfactory continuous operation under the following climatic conditions as per IS: 2026 (Part- I) latest revision.

i) Peak ambient temperature : 50°C

ii) Maximum yearly weighted average ambient temperature : 35°C iii) Maximum relative humidity : 95 %

(Some time approaches saturation points) iv) Minimum relative humidity : 10% v) Average number of thunder storm days per annum : 40

vi) Average number of rainy days per annum : 90 vii) Average annual rainfall : 125 cm viii) Number of months of tropical monsoon conditions : 3 Months ix) Maximum wind pressure : 100 Kg/mt² x) Altitudes : Not exceeding 1000 mtrs

1.4 PRINCIPAL PARAMETERS 1.4.1 The Transformer shall be suitable for outdoor installation with three phase 50 Hz 11 KV system in which the neutral is effectively earthed and should be suitable for outdoor service as step down transformer under fluctuations in supply voltage up to (+) 10% to minus (-) 15 % and frequency variation of +/- 3% from the rated frequency. The transformer should be suitably designed for with-standing the unbalanced voltages developed due to single phasing operation during load regulatory measures in 11KV distribution system. It should be capable of withstanding the disturbance of back e.m.f., magnetic characteristic and consequential mechanical inter-play of forces, if any, under such single phasing. 1.4.2 The 25 KVA Transformer shall confirm to the following specific parameters:

i) Continuous rated capacity : 25 KVA ii) System Voltage (Max.) : 12.5 KV iii) Rated HT voltage : 11 KV iv) Rated LT voltage : 433 V (P-P) / 250 V (P-N) v) Frequency : 50 Hz vi) No. pf phases : THREE vii) Primary connection (HT) : DELTA viii) Secondary connection (LT) : STAR ix) Vector Group : Dyn-11 x) Percentage impedance at 75°C : 4.5 % xi) Taps (off circuits) : TAPS NOT REQUIRED xii) Type of cooling : ON AN xiii) Fault level of the system : 500 MVA



1.4.3 Primary winding shall be DELTA connected and the secondary winding shall be STAR connected (vector symbol Dyn-11), so as to produce a positive displacement of 30° from the primary to the secondary vectors of the same phase. The neutral of the secondary winding shall be brought out to a separate insulated terminal. The transformers shall be Aluminum wound (EC grade).

1.4.4 The transformer shall be designed and constructed to withstand without damage the thermal and dynamic stresses of an external short circuit. The Manufacturer / Bidder/manufacturer shall furnish all relevant design data and calculations in support of having fulfilled this requirement as stipulated in IS:2026 (Part-I) 1.5 NO LOAD VOLATGE RATIO:

The No load voltage ratio(s) shall be 11000/ 433 Volts.

1.6 LOSSES: 1.6.1 The No-load Loss and Load Loss for 11 KV Distribution Transformers of 25 KVA rating shall not exceed the values indicated below:

RATING (KVA) MAX. NO LOAD LOSS IN WATTS (Fixed Losses)

MAX. LOAD LOSS IN WATTS (at 75°C)

25 100 685 1.6.2 The above specified loss values are maximum guaranteed, without any positive tolerance. In case the actual loss values exceed the above guaranteed values, the transformers shall be rejected at the risk, cost and responsibility of the Bidder/manufacturer. 1.7 TEMPERATURE RISE: 1.7.1 The temperature rise test shall be conducted by feeding total guaranteed losses calculated at 100°C as against 75oC in the ISS and tested in accordance with IS:2026 or equivalent standards and the same shall not exceed the limits of 50°C above ambient temperature (measured by resistance method) for transformer windings and 40°C above ambient temperature (measured by thermometer) for top oil. In case the temperature rise exceeds the above values, transformers shall be rejected at risk, cost and responsibility of the Bidder/manufacturer. The losses fed during temperature rise test for 25 KVA rating shall be as under:

RATING Total Losses to be fed (No load losses + Load Losses corrected to 100oC) 25 KVA 100 + 742 = 842 Watts

1.7.2 It must be noted carefully that readings for hot resistance after shut down shall be taken separately for HV & LV windings, which means, after completing the readings for one winding (HV or LV), the transformer shall be connected again and rated current passed for another 60 minutes (min.) and shut down taken again to take hot resistance readings for the remaining winding. This is in line with the requirement of CBIP manual, to ensure proper resistance v/s time curves. 1.7.3 The Hot spot temperature at annual weighted average ambient temperature of 35o C shall not exceed 98o C, when calculated as per IS: 2026 (Part-II)

However, the transformer shall be designed for class ‘A’ insulation.

1.8 UNBALANCE CURRENT The maximum value of unbalanced current in transformers shall not exceed 2% of full load current. 1.9 IMPEDANCE: The percentage impedance at rated current and at 75°C shall be 4.5 % with (+/-) 10 % tolerance. 1.10 TAPPINGS:

No taps are to be provided in these transformers.



1.11 FREQUENCY: Transformers shall be designed for normal frequency of 50 Hz, but shall be capable of giving the rated output with the variation of (+/-) 3 % from the rated frequency. 1.12 ELECTRICAL CLEARANCES (A) EXTERNAL (IN AIR) Minimum external electrical clearances after mounting the bimetallic terminal connectors in position shall be maintained, as under; however, positive tolerance shall be acceptable without any ceiling.

Voltage Medium Clearance Phase to phase Phase to earth

11000 Volt A I R 255 mm 140 mm 433 Volt A I R 75 mm 40 mm

B) INTERNAL (IN OIL)

The following minimum internal clearances shall be maintained as per details given hereunder:

PARTICULARS 25 KVA a) Between HT outside surface & tank inside (non bushing side) 25 mm b) Between HT outside surface & tank inside. (HV bushing side) 40 mm c) Between HT outside surface & tank inside. (LV bushing side) 25 mm d) Between HV windings & yokes (end insulation) 20 mm e) Between LV windings to core(Bare conductor) 3.5 mm f) From top of yoke to inside of top cover of tank (with gasket) 125 mm g) Between LT/HT winding (Radial bare conductor Clearance ) 11 mm h) Phase to Phase Clearance between HV limbs 10 mm

The aforesaid external and internal clearances are minimum clearances and no negative

tolerance on these clearances shall be allowed. 1.13 TEST VOLTAGE: Transformers shall be capable of withstanding the power frequency and impulse test voltage prescribed below:

Nominal system Voltage (RMS)

Highest system voltage (RMS)

Impulse withstand voltage

Power frequency test voltage in (RMS)

11 KV 12.5 KV 75 KV (PEAK) 28 KV 0.433 KV ---- ---- 3 KV

The transformer shall have fully insulated windings designed for the above impulse level. 1.14 HEAT DISSIPATION (COOLING) / RADIATOR CALCULATIONS & E T R (ELLIPTICAL TUBE RADIATORS) PLACEMENT 1.14.1 The transformers shall be capable of giving a continuous output without exceeding the specified temperature rise as indicated in para 1.7 above. Elliptical tube radiators of section 57 of gauge 18 (with tolerance as per relevant ISS) or pressed steel radiators having sheet thickness of 1.20 mm (with tolerance as per relevant ISS) on the transformers shall be acceptable. 1.14.2 The radiator tubes shall be arranged in two equal banks fixed at two opposite non bushing sides. The header pipe connecting radiator bank to the tank shall be rectangular in shape with approximate size of 100x20 mm (for elliptical tube radiators) or the header pipe connecting radiator flange to the tank shall be of round pipe of dia 32 mm (for pressed steel radiators). The placement of top header pipe to the tank body shall be above the top of yoke, to facilitate cooling for hot oil sump over top yoke.



1.14.3 Cooling area of the tank/radiators should be sufficient to dissipate the guaranteed losses (at 100°C) satisfactorily. Necessary calculations in this regard shall be furnished by the Bidder with their Bid. For the purpose of heat dissipation calculations, the following criteria shall be adopted:

i) Plain surface of tank – 500 W / m2 (Note: The area of top/bottom tank surface, headers, HV/LV bushing pocket shall not be

considered for purpose of above calculations). ii) Elliptical tube of section 57 -- 55 watts/meter length. 1.14.4 There shall not be any price preference for providing of either type of radiators. 1.15 WINDING AND INSULATION: i) MATERIALS:

Double paper covered Aluminum conductors shall be used for 11 KV class transformer of 25 KVA rating. The covering shall conform to IS: 6162 (part I & II). ii) CONSTRUCTION:

The High-tension windings shall be concentric with the Low-tension windings. The arrangement of the windings shall be robust in electrical and mechanical construction and shall permit free circulation of oil and avoid hot spots. The LT conductor shall be rectangular in shape. Two layers of electrical grade insulation craft paper of 2 mm thickness or one layer of minimum 4 mm thickness shall be used for interlayer insulation both for HV and LV Coils. Insulation cylinder made from electrical grade pre-compressed board(s) having minimum total thickness of 1.5 mm shall be used between HV and LV windings. Alternatively, 20 mm press Han paper making thickness of the cylinder 1.5 mm having similar electrical properties may also be used. For phase barrier, 2 Nos. of 1 mm thick press board shall be used for covering the tie rods. Tie rods shall be covered by craft paper of suitable size in addition. 2 mm press board shall be used for base support insulation and core clamping channel insulation. For bottom and top yoke insulation, only PC board of min. 2 mm thickness will be used. Also, vertical spacers between HV and LV coils and radial spacers (tick leys)/ blocks etc. shall be of PC Board only. Top layer of all HV coil shall be given one coat of air drying insulation varnish.

A tolerance up to plus/minus 1% shall be permissible on ID and OD and axial length of HV and LV coils. However, the above tolerances are subject to maintaining the min. required clearances. The material and thickness of various insulation provided for phase barrier, foot plate insulation, yoke insulation and core clamp insulation shall be clearly indicated in the drawing and in any case shall not be inferior to those used in type tested transformers.

Minimum number of coils on HV side shall be 4 (four) per phase for 25 KVA rating transformers. Dovetailed shaped radial spacers shall be placed between HV coil sections, suitably – locked with vertical spacers around the circumference of the coils. The number of such spacers shall be minimum 4(four). iii) INSULATION MATERIAL

Electrical grade insulating Kraft paper of only Tribeni / Ballarpur / Cauvery or equivalent/ better make shall be used subject to approval of the Employer. Press Board used shall be of senapathy whitely / Raman make or equivalent/ better quality subject to approval of the the Employer. Perma wood or haldu wood blocks shall be used for Top and Bottom yoke insulation. iv) CONNECTIONS AND TERMINATIONS:

A) HV Winding:



The following method shall be adopted for taking out HV connections- a) The coil series connections shall be made by soldering / brazing only, after completely

removing the insulation from the ends.

b) Starting and finishing leads of HT coils shall be covered with empire sleeve(s) of proper size. These leads should be clamped with the body of the winding with the help of cotton twine during manufacture of the coils.

c) All delta leads from the HT coils as well as HT line leads shall be taken out through multiple paper covered (MPC) copper wires of sufficient cross section area to impart the desired mechanical strength. The current density in HV lead wire shall not exceed 0.8 A/mm². These lead wires shall be provided with multi layer paper insulation of minimum 1.0 mm thickness i.e. increase in diameter due to paper insulation shall not be less than 2 mm. The layer of glass sleeves/ glass tape shall also be provided on the delta MPC wire and it should be further covered with craft paper.

d) All the above leads shall then be clamped tightly with cotton twine directly on to the special frame/ bracket making “Pie” shape connection. This structure could be made up of Bakelite/ Permalli wood/ laminated PC board flats, having minimum size of 25x4.5 mm. Line leads leading to the HV bushing terminals shall be directly clamped to the horizontal support bar of the “Pie” structure so that any tension which may develop in the HT leads due to jerks or at the time of making the connection, is not passed to the HT coils.

e) Delta joint and lead from delta joint to bushing rod shall be made by brazing only. B) LV Winding : a) The LV connection shall be taken out by cut on the top yoke channel duly reinforced to

compensate for the mechanical strength. b) The layers in LT Coil may be either even or odd in numbers but minimum layers shall be two. c) LV star point shall be formed of Aluminum flat of sufficient strength. Leads from winding shall

be connected to the flat by brazing. d) Firm connection of LT winding to bushing shall be made of adequate size of “L shape flat”.

Connection of LT coils to L shape flat shall be by brazing only. e) “L” shape Flat shall be clamped to LV Bushing metal part(s) by using nut, lock nut and washer. f) Neutral of the Secondary winding (LV) shall be brought out to a separate insulated

bushing. g) For Aluminum windings, L&T, ALKAPEE Aluminum brazing rods with suitable flux will be used.

30.16 CORE CONSTRUCTION & CORE COIL ASSEMBLY DETAILS: (i) The core shall be of high grade cold rolled grain oriented (CRGO) annealed steel laminations, having low loss and good grain properties, coated with hot oil proof insulation, bolted together to the frames firmly to prevent vibration or noise. All core clamping bolts shall be effectively insulated. The complete design of core must ensure the permanency of the core losses with continuous working of the transformers. The value of the flux density allowed in the designs and grade of laminations used shall be clearly stated, along with the curves. The transformer core shall be constructed out of the prime class of materials. CRGO Lamination used shall be of prime grade and not second grade steel laminations. (ii) It will be mandatory for all the transformer manufacturers to use only PRIME grade CRGO Laminations with specific loss of 0.89 watt per kg. at 1.5 Tesla or any other combination of better grades with any thickness subject to maximum specific loss of 0.89 watt per kg. at 1.5 Tesla will also be acceptable. The bidder shall furnish the core loss (watt/Kg.) and power (VA/Kg) curves of the laminations used. The core shall be properly stress relieved by annealing in inert atmosphere. The transformer shall be suitable for over fluxing (due to combined effect of voltage and frequency) upto 12.5% without injurious heating. The operating flux density shall be such that there is a clear safe margin of 12.5%. over the fluxing limit. (iii) Full mitered core construction technique shall be adopted. Top yoke & bottom yoke pieces shall all be in one single piece and no cut pieces shall be acceptable. The cross sectional area of yoke & limb shall be approximately same. (iv) Transformer core shall not get saturated for any value of V/f ratio to the extent of 115% of the rated value of V/f ratio (i.e. 11000/ 50) due to combined effect of voltage and frequency without injurious



heating at full load conditions. The bidder shall furnish necessary design data in support of this situation. (v) Flux density at rated voltage and frequency of core and yoke shall not be more than 1.60 Tesla. The Over fluxing shall be limited to 12.5 % of rated value. The No Load Current (magnetizing current) at rated voltage and at 112.5% of rated voltage shall not exceed the values given below:

Maximum permissible magnetizing current in percentage of rated full load current

Transformer Capacity (In KVA) At 100% rated voltage At 112.5% rated voltage 25 3.25 6.50

(B) CORE-COIL ASSEMBLY: The core joints shall be interleaved and with full miter design, as mentioned above. Ample provision for free circulation of oil in the radial gap between the core & LV coils shall be made. Eyes or lugs of sufficient size shall be provided for lifting core and winding assembly out of the tank. The core shall be effectively earthed through tinned copper earthing plate bolted on core frame channels, after removing the channel paint. For top yoke channels, if cut or holes are made for taking LV connections, suitable reinforcement to channels shall be made by providing adequate size of MS Flat of the thickness not less than 6 mm. On the core-coil assembly, core clamping channels, tie rods, core studs, spacers, assembly base supports, etc. shall be provided as per details given hereunder:

Sr. No.

Item Particulars

a) Tie rods Minimum 4 Nos. of 12 mm each properly insulated and covered with Kraft paper. Tie rods shall also be provided with lock nuts.

b) Core studs Minimum 4 Nos. of 12 mm each properly insulated and covered with Kraft paper. The core studs shall also be provided with lock nuts.

c) Spacers Minimum 4 Nos. dovetail type with min. peripheral coverage of 30%.

d) Support of core assembly base

2 Nos. MS channels of 75x40 mm.

e) Channels for clamping core coil assembly

4 MS Channels of 75 x 40 mm size (applicable for CRGO transformers)

Guides on all the four sides shall be provided to prevent shifting of the active parts and thereby accidental touching the tank. Alternatively brass nut arrangement at the top of core coil assembly to lock the same with the transformer tank be provided.

The assembly fixing brass nut(s) are to be welded, 20-30 mm off the centre line (and diagonally) of the tanks, so that assembly movement during transport etc. is prevented. MS Channel, tie Rods etc should be painted with hot oil and corrosion resistant paint after phosphate. All core-coil assembly shall be punched on core channel / a identity plate welded on core channel with following details: 1. Name of Bidder/manufacturer: 2. Order / TN No: 3. Rating:

In case the above marking is not found on the core assembly of physically opened transformer selected for physical verification during final inspection then no further inspection shall be carried out and re-inspection charges shall be payable by the Bidder/manufacturer.



1.17 TRANSFORMER TANK: (a) Transformer tank shall be rectangular in shape, robust in construction and with adequate strength to withstand the pressures developed at the time of severe fault conditions. The tank body shall be suitably stiffened to achieve the objective. The tank sheet shall be electrically welded both from inside and outside to impart proper mechanical strength and to prevent leakage of oil. All joints of tank and fittings shall be oil tight and no bulging shall occur during service. The tank design shall be such that the core and windings can be lifted freely. The tank plates shall be of such strength that the complete transformer when filled with oil may be lifted bodily by means of lifting lugs provided. The stiffeners shall be welded full length. All the welding shall be continuous. The top cover plate shall be sloping down by more than 15 mm, opposite LV bushings side. The top cover instead of bending shall be extended by 5 mm by all the sides beyond the flange of the top cover. Accordingly length of the lifting hooks shall be extended. The top cover shall have no cut at point of lifting lug. No negative tolerance in the tank dimensions is acceptable in actual supply. The tank shall be fabricated by welding at corners. No horizontal or vertical joints in tank side walls and its bottom and top cover will be allowed. (b) Minimum size of MS Sections to be used in construction of transformer tanks shall be as under:

Sr. No.

I T E M S 25 KVA

1 Tank Cover plate thickness (mm) 5.0

2 Tank Sides wall thickness (mm) 3.15 3 Tank bottom plate thickness (mm) 5.0 4 No. of stiffeners (To be welded with one face while the

other side of the angle forms inverted “L”) 1

5 Conservator body (mm) 2.0 5 Size of M. S. stiffener (mm) 40x40x 6 angle 6 Tank Top flange size (mm) 50 x 6 Flat

7 Cover Bolt Size M10/ 3/8 x 1.5” 8 Cover Bolt spacing (Maximum) 75 mm 9 Lifting lugs 2 Nos.

8t mm flat 10 Tank Base Channel (ISMC Type) 2 ( 75 x 40 mm)

NOTE: Each cover bolt shall be complete with two flat washers, one nut and one spring washer. The above mentioned M S sections shall be subject to tolerance as per ISS. (c) Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate of 8 mm thickness, suitably reinforced by vertical supporting flat welded edge wise below the lug on side wall shall be provided, these shall be so extended that cutting of bent plate is not required (d) Top cover gasket & Bolt :

i) The gasket provided in between top cover plate and tank shall be of min. 6 mm thick neoprene rubberized oil resistant cork sheets conforming to type B or C as per IS:4253 part II.

ii) G.I. Nut bolts shall be of size M 10 x 40 mm / 3/8x1.5” long with two flat washers, suitably spaced (as specified) to press the cover.

iii) Height of the tank shall be such that minimum clear height of 125 mm is achieved between top of yoke and under side of the tank cover (with gasket in place).

iv) All steel screws, nuts and fasteners exposed to atmosphere shall be either galvanized or cadmium plated or electroplated.

v) All sealing washers / gaskets shall be made of oil and heat resistant neoprene or nit rile rubber. Gaskets made of natural rubber sheet are not permissible. The

minimum thickness of gaskets shall not be less than 6 mm for tank cover and 4mm for HT/LT gasket washers.

vi) Talbros make neoprene/nitrile based rubberized cork sheet – grade RC-70-C shall only be used as gasket material. Alternatively, other makes of gaskets having type designations as under can also be used, if ‘Talbros’ make gasket is not available:



S. No.

Name of the firm Commercial name of gasket manufactured by the firm.

1. M/s. Nu-Cork Products P. Ltd. Gurgaon

Nu-Cork (Neoprene) Nu-Cork 999 RC-70-C

2.

M/s. Bharat Corrub Ind. Vadodara Chetak (Neoprene) RC-70-C

3.

M/s. Grindbeck. Gujarat Zebra (Neoprene) RC-70-C

4. M/s Goodwill Rubber Ind. (P) Ltd., Calcutta.

Mayur (Neoprene) RC-70C

(e) Tank shall be reinforced by continuously welded angle on all the four sides of the walls, on the edge of tank, as specified above. The permanent deflection shall not be more than 5 mm upto 750 mm length and 6.5 mm up to 1250 mm length when transformer tank without oil is subjected to the vacuum of 250 mm of Mercury. (f) PAINTING & FINISHING:

Steel surface shall be prepared by sand / shot blast or chemical cleaning including phospating, as per IS 3618. Heat resistance paint (Hot oil proof) shall be provided inside the tank. On external surface, one coats of thermo-setting powder paint or 2 coats of Zinc chromate followed by two coats of synthetic enamel paint of dark admiral grey shade, confirming to shade No. 632 of IS: 5-1961, shall be applied. The requirement for paint and the material to be used shall be as below.

Paint Type Area to be Painted No. of coats a) Powder Paint b) Thermo Setting Powder

Inside Outside

01 01

LIQUID PAINT a) Zinc Chromate (Primer) b)synthetic Enamel or powder coating (finish coat) c) Hot Oil Paint

Outside Outside Inside

02 02 01

All steel screws, nuts and fasteners exposed to atmosphere shall be either galvanized or

cadmium plated.

1.18 FITTINGS & ACCESSORIES: The following standard fittings shall be provided on each transformer:

a) Earthing terminals of M10/ 3/8x1.5” with tinned lugs and symbol – (2 Nos.) b) Lifting lugs – (2 Nos. for main tank). c) Rating and terminal marking plate (non-detachable), details to be included

in one plate only. The plate shall be of stainless steel only, with details clearly marked - (1 No.)

d) Bi-metallic terminal connectors on HT/LT bushings and it may be ensured before dispatch that connectors are fitted.

e) Oil level gauge of minimum 150 mm length of prismatic glass, indicating three positions of oil, marked as follows, shall be provided:

1) -5 °C - Min. 2) 30 °C - Nor. 3) 98 °C – Max.

f) Silica Gel Breather shall be Aluminum/ metal – (1 No.) g) Thermometer pocket, 12.5 mm dia with cap. shall be provided –– (1 No.)

h) HV Bushings. These shall be of 17.5 KV/250 A class, with non adjustable, single gap type arcing

horns – (3 Nos.)

i) LV Bushings. 1.1 KV class, 250A (M12 stem) – (4 Nos.)



j) Under carriage: For transformers of 25 KVA rating shall conform to REC specifications.

k) Brass rod 12 mm diameter for HT – (3 Nos.)

l) Brass rod 12 mm diameter for LT – (4 Nos.)

Note: LV/ HV Connectors shall not be the integral part of the bushing stems. 1.19 CONSERVATOR: 1.19.1 The oil gauge and the breathing device shall be fixed to the conservator. In addition, the cover of the main tank shall be provided with a self-sealing pressure release device designed to operate at minimum pressure of 8 PSI (0.564 Kg./cm. Sq.) to enable release of air trapped within the main tank, unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. The conservator shall be of cylindrical shape and it should be provided above the HV bushing with a minimum clearance of 50 mm and suitably inclined to maintain the clearance. 1.19.2 The total inner volume of conservator shall be minimum 10 ltr. for 25 KVA transformer. The inside diameter of the pipe connecting the conservator to a main tank shall be min. of 30 mm and it should be projected into conservator in such a way that its end is approximately 25 mm above the bottom of conservator so as to create a sump for collection of impurities. The min. oil level (corresponding to – 5 deg. C.) should be above the sump level. The connecting pipe from conservator tank to main tank shall have a sloping flap so that oil falling from pipe shall not fall directly on the active job.

1.20 SILICAGEL BREATHER: 1.20.1 Body of breather shall be of Aluminum/ metal and inside container for Silica gel shall be of tin sheet. The breather shall be only from reputed and approved manufacturer and as per the approved drawing. The gel capacity shall be of 250 grams. Inverted U shape pipe shall be used for breather. Mounting arrangement of the breather shall be flanged/ threaded type as per details given in the illustrative drawing attached. 1.20.2 The design shall be such that the condition of Silica gel is clearly visible from a distance, even after years of service. 1.21 H V BUSHING TERMINAL DETAILS : 1.21.1 3 Nos. 17.5 KV / 250 A class bushings, conforming to IS:3347 & IS:2099, shall be fitted on a pocket made on top cover. These pockets shall be such that the HV bushing is tilted more towards the HV side. The bushing of R & B phases may be tilted sidewise also to maintain the required electrical clearances. 1.21.2 The clamping ring of HV bushing shall be of galvanized MS Sheet having minimum thickness of 1.6 mm. The total weight of all the 12 Aluminum caste member of HV bushing shall not be less than 210 grams. 1.21.3 The inner porcelain portion of bushings shall be projecting approx. 50% of the length inside the conical pocket.

1.21.4 The arcing horn(s) shall be single gap and fixed type. HV bushings shall be of reputed make such as BEPCO, JAYSHREE, WSI, SESHASAYEE or any other make - approved by the Employer. The HV bushings shall generally conform to IS: 3347 and IS: 2099. Embossing showing the manufacturer’s name and month & year of manufacture shall be clearly visible on HV bushings, even after fixing on transformer(s).

1.21.5 As mentioned earlier, suitable bi-metallic connectors shall be provided having capacity of about 1.5 times the rated current of the transformer, as per drawing enclosed.

1.22 L V BUSHING TERMINAL DETAILS:

1.22.1 LV Bushing side shall be opposite to the HV Bushing side. 4 Nos. LV Bushings (1.1 KV/ 250 A) shall be mounted on a special pocket on the tank wall. Projection of the LV pocket shall be such that



inner portion of the LV stem shall not project more than 20 mm inside the tank, to facilitate unhindered lifting of the core coil assembly. Bushing stem of M12 size shall be of brass. Rest of the components shall conform to the requirement of IS:3347 (Part I/section 2). The LV bushings shall be of reputed make such as JSI, JAIPUR GLASS or any other make approved by the Employer. The LV bushings shall generally conform to IS: 3347 and IS: 7421. 1.23 TRANSFORMER OIL:

30.23.1 The transformer shall be supplied complete with first filling of EHV Grade transformer oil, up to the normal oil level. The oil shall conform to IS: 335-1983 (latest amended) and should be ISI marked and having the specified aging characteristics. 1.23.2 The transformer oil sample taken from the transformer shall be subjected to testing as per provisions of IS:1866.

1.23.3 The oil manufacturer’s test certificate shall be made available at the time of inspection to the inspecting officer. 1.24 IDENTIFICATION DETAILS: a) Rating & terminal marking plate: Each Transformer shall be provided with non detachable name, rating and terminal marking plate fitted in a visible position. All details shall be given on one plate. Material of the plate shall be stainless steel only. Thickness shall be 0.9 mm (with a tolerance of ±0.1 mm). The plate shall be made absolutely un-detachable either through welding or riveting or through any other approved method. Each HV & LV terminal shall be duly marked with its terminal numbers. (e.g. HV terminal with capital letter 1U, 1V, 1W and LV terminal by corresponding small letters) 2u, 2v, 2w and the neutral terminal by 2n). In the diagram to be given on the name plate, the relative position of various terminals- when viewed from top – shall be clearly shown. Dispatch instruction will not be issued, unless all these details are verified by the Inspecting Officer. Besides other particulars, following details shall also be given on the name plate:

i) P.O. No. - Month & year. ii) Sr. No. of transformer. iii) Date of dispatch - month & year iii) Date of expiry of guarantee period – month & year iv) Maximum Guaranteed No Load & Load Loss Figures v) Recommended fuse sizes for HV & LV sides. vi) Name & Full address of the manufacturer. vii) Weight of oil (In Kg). viii) Total Weight (In Kg). ix) Vol of oil (In Liter) x) Rating of the transformer. xi) Impedance volt. (%). xii) Volts at HV&LV. xiii) Frequency (Hz) xiv) Vector group (Dyn11)

ALL DETAILS ON THE NAME RATING AND DIAGRAM PLATE SHALL BE INDELIBLY MARKED i.e. BY ENGRAVING, STAMPING or PUNCHING. b) Identification Plate: M.S. plate of size 75 x 75 x 2.5 mm having following details punched with letters of size 8mm X 6mm shall be continuously welded to the main tank body below the middle HV bushing and on top cover of tank in clearly visible position :

MPPKVVCL ……… KVA , S.NO. ………. MAKE …………….

c) Identification mark:- Serial Number of Transformer is to be engraved on transformer tank just below the name plate with the letter size of 10 mm x 8 mm.



1.25 GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR TRANSFORMER:

1.25.1 Guaranteed Technical Particulars of the transformer offered shall be furnished in A-4 size paper by the Bidder in the proforma appended herewith. Complete details shall be furnished. Tolerances on weight, quantity and dimension figures shall be ± 5% at the tender stage, subject to maintaining the minimum electrical clearances as per the specification. However, no negative tolerance shall be allowed on the short circuit type tested design. Electrical performance data shall be subject to tolerances as per ISS, unless otherwise specified in this specification. However, the No Load loss and Load loss figures shall be maximum guaranteed without any positive tolerance. 1.26 TYPE TEST CERTIFICATES:

1.26.1 The contractor/manufacturer shall furnish type test certificates in accordance with IS:2026 (Part I to III) for the offered transformer, which should not be more than 3 years old as on the date of submission of Bid.

i) Short circuit test for dynamic and thermal ability: The short circuit test for dynamic and thermal ability shall be arranged at CPRI, Bangalore/ Bhopal or ERDA, Vadodara on one unit of each rating.

ii) Impulse voltage withstand test: The impulse voltage withstand test shall be arranged at any testing house accredited to NABL for the purpose of impulse test.

1.26.2 The cost of above Type Tests shall be borne by the Contractor/approved manufacturer. 1.27 DRAWINGS AND OTHER DOCUMENTS:

1.27.1 The Bid shall be accompanied with the following drawings / Calculation sheets, as per the offered designs. The drawings shall be only on A-3 (420 x 297 mm) size paper and calculation sheet shall be on A-4 size paper only.

a) Name rating / diagram plate drawing. b) Outline and general arrangement drawing. c) Core-coil assembly drawing. d) Core section (for limb and yoke) along with flux density calculation sheet / drawing. e) Cooling area calculation sheet. f) Thermal Ability short circuit calculation sheet. g) Core loss and magnetization curves of the laminations. h) Heat dissipation calculations (heat dissipation by tank walls excluding top and bottom

should be 500 W/sq. meter. 1.28 QUALITY ASSURANCE PLAN: 28.1 The Contractor/manufacturer shall furnish the details in respect of the items specially indicated in the schedules prescribed herein and annexed with this specification, failing which the offer is liable for rejection. 1.29 INSPECTION AND TESTING:

The inspection and testing shall be conducted at the place of manufacture. The transformers shall be completely assembled and tested at the factory. The inspection may be carried out by the Employer at any stage of manufacturing.

1.30 STAGE INSPECTION: 1.30.1 The Employer’s representative may carry out stage inspection of the transformers during manufacturing/ assembling stage. The Employer shall have absolute right to reject the raw material/ component/ sub assemblies or complete equipment not found to be conforming to the requirement of specification or being of poor quality/ workmanship. The stage inspection will particularly include the following tests/ checks besides the general routine tests to be conducted during manufacturing stages as per manufacturer’s standard practice.



a) Physical inspection/checking of winding, insulating material, core material for annealing and prime quality and other accessories / fittings of Transformer.

b) Measurement of core area and flux density. c) Verification of H.V. & L.V. coils, Conductor size, I.D., O.D. Axial length, weight, insulation

covering etc. d) Measurement of thickness of tank plates (Top, bottom and sides) and to conduct Air pressure & vacuum tests as specified in the specification, to ensure the adequate strength of the Transformer tank body. e) Sample testing of core material for checking specific loss and thickness of core plates. f) Visual and dimensional check during assembly stage of core. g) Check for proper provisions of spacers and bracings to arrest the movement of core and winding assembly inside the tank. h) Check complete transformer against approved outline drawing, provision for all fittings, finishing etc.

1.30.2 The Employer at his option may collect the sample of the following raw material/ component for independent testing:

a) CRGO Laminations - One specimen sheet of 300-500mm length and 50- 75mm width (for each lot). b) HV winding wire - 1250 mm length specimen for each type. c) LV winding wire - 1250 mm length specimen for each type. d) Transformer oil. - 2 samples of 5 liters each. 1.30.3 To facilitate stage inspection, the Bidder/manufacturer should intimate complete schedule of manufacturing programme of the transformers preferably 15 days in advance. At least 25% of the transformers shall be offered in the shape of finished core - coil assembly. The inspecting officers during the course of stage inspection may seal this core - coil assemblies. 1.30.4 . 1.31 ROUTINE/ ACCEPTANCE TESTS: 1.31.1 All the assembled/ finished transformers prior to dispatch shall be subjected to routine tests as per IS: 2026. Minimum 10% of the offered lot size samples subject to minimum 5 Nos will be taken for routine and acceptance tests. The Bidder/manufacturer shall invariably furnish manufacturer’s routine test certificate along with inspection call of the offered transformers for pre-dispatch inspection. The inspection offers without furnishing of routine test certificates as per ISS of all the transformers offered for final inspection shall not be entertained, and any delay on this account shall be to Bidder/manufacturer’s account. 1.31.2 The selected samples shall be subjected to the following routine / acceptance tests at the manufacturer’s works in accordance with the relevant ISS: 1. Insulation resistance 2. Separate source voltage withstand test 3. Induced over voltage withstand test 4. Measurement of windings resistance cold (at or near the test bed temperature) 5. Measurement of Voltage ratio and check of voltage vector relationship 6. Measurement of Impedance voltage and load losses at rated current and normal frequency. 7. Measurement of No load losses at rated voltage and normal frequency. 8. Measurement of No load current at 100 % and 112.5% of rated voltage and normal frequency. 9. Checking of rating and terminal marking plate. 10. Checking of weights, dimensions, fittings and accessories, tank sheet thickness, oil quantity,

material, finish, paint thickness and workmanship as per purchase order and contract drawings.



11. Physical verification of core – coil dimension, internal clearances, provisions of required oil ducts in the HV and LV winding, conductor sizes, individual weights of HV and LV winding core laminations etc., with reference to contract drawings and type test report(s) by dismantling selected unit(s). The physical verification shall be conducted on units equivalent to one unit per 25 Nos or part thereof of offered quantity randomly selected from the offered lot. The dismantled unit(s) after re-assembly shall be accepted by the Employer after routine testing in presence of his representative.

12. Oil dielectric strength (break down voltage) test. 13. Checking of manufacturer’s test certificates and invoices for major raw materials shall be done

and copies thereof duly signed by Bidder/manufacturer’s representatives and inspecting officers shall be enclosed with the inspection report.

1.31.3 Following tests shall also be carried out at manufacturer’s works on one complete unit of 25 KVA Transformer unit :

i) Temperature rise test (in the first lot and may be repeated in subsequent lots if

desired by the Employer). ii) Air pressure test on empty tank of transformer opened for physical verification test.

(See note below) iii) Measurement of unbalance current. iv) Magnetic Balance Test (See note below) v) Oil Leakage Test (See note below)

1.31.4 Preferably Fifteen days clear notice shall be arranged for pre-dispatch inspection by Employer’s representative.

1.31.5 After successful inspection, the inspecting officer shall seal all the inspected transformers by numbered seals on diagonally opposite bolts of top cover for identification. Before sealing, the inspecting officer will ensure that all the offered transformers are complete and duly fitted with name, rating and diagram plate, identification plate (on tank body & Top cover) as specified in this specification. NOTE:

i) INSULATION RESISTANCE MEASUREMENT:

Insulation resistance of selected samples shall be measured with a 2500 V Megger, of standard make such as M/s AVO, M/s Sakova, M/s Wako, M/s Evershed, Vignole or Metrawatt. The minimum insulation resistance, in Mega Ohms, shall be as indicated in the table below:

200 C. 300 C. 400 C. 500 C. 600 C. 11000 Volts (HV)

800 400 200 100 50

433 Volts (LV)

400 200 100 50 25

ii) AIR PRESSURE TEST :

This test shall be conducted as type test at the time of inspection of first lot, at the manufacturer’s works. The pressure gauge and vacuum gauge shall be duly calibrated and sealed by an independent recognized test lab(s).

The test procedure shall be as detailed below : The tank shall be fixed with a dummy cover with all fittings including bushings in

position and shall be subjected to air pressure of 0.8 Kg./ cm² (gauge pressure), for 30 minutes. Permanent deflection of flat plate, after pressure has been released, shall not exceed

the values given below: Length of plate up to Deflection 750 mm 5.0 mm 751 to 1250 mm 6.5 mm



iii) MAGNETIC BALANCE TEST: This test shall be conducted as an additional test on one sample transformer from each lot

offered for inspection.

The application of low voltage to the middle limb will induce approximately equal voltages on the two end limbs. The application of voltage to the end limbs will induce greater voltage in the middle limb and less voltage in the other end limb. Uniformity of induced voltages shall confirm the healthiness of the transformer windings. The procedure for the test shall be as under :

a) Apply 250 Volts between LV terminals 2u-2n and measure voltages between 2v-2n & 2w –2n.

b) Apply 250 Volts between 2v-2n and measure voltages between 2u-2n & 2w-2n. c) Apply 250 Volts between 2w-2n and measure voltages between 2u-2n & 2v-2n. The measured voltages shall satisfy the conditions detailed as above.

iv) OIL LEAKAGE TEST: The oil leakage test shall be conducted on one unit selected from the offered lot. Transformer complete in all respects shall be subjected to the pressure corresponding to 0.5 Kg / cm² and maintained for three hours. No leakage should occur. 1.32.3 The programme indicating date and place of type test(s), be intimated to enable Employer, if so decides, to depute his representative to witness the test. The testing house shall be advised to arrange to send type test results directly to Employer along with drawings duly attested by the testing authority for scrutiny and approval. The type-tested transformer(s) shall also be accepted as part of the supplies. 1.32.4 The requirement of arranging short circuit & impulse voltage withstand test shall however, not to be insisted on the Bidder/manufacturer who has arranged Dynamic & Thermal Ability to withstand Short Circuit Test/ impulse voltage withstand test within last 3 years as on the date of opening of the tender on similar design and make.

1.33 RANDOM SELECTION AND TESTING (RST):

(i) Inspection of material before dispatch or waiver of inspection will, however, not relieve, the Bidder/manufacturer from his responsibility to supply the material strictly in accordance with the specification. The Employer shall have option to test the samples selected at random from the lot of 25 No received at site and shall be subjected to routine testing as per IS:1180 and 2026 (with latest amendments) at MTRU, Jabalpur/ CPRI, Bhopal, CPRI, Bangalore/ERDA, Vadodara/any other NABL accredited Laboratory.

(ii) In case the selected transformer from the first lot fails in routine test, one unit from the

next lot shall be sent to the identified laboratory for carrying out routine tests at Bidder/manufacturer’s cost. In case the transformer fails again in any or all routine test, no further supply shall be accepted. The transformers available at site supplied against the current order shall have to be taken back by the Bidder/manufacturer at his own cost.

(iii) The Bidder/manufacturer will have to carry out suitable improvement in the design of the

transformer and get it type tested in presence of Employer’s representative at his own cost. It is only after the transformer successfully passes the type test, the supplies shall be resumed which shall again be subject to random test as above before acceptance of the lot. This process will continue in subsequent lots also. Further, the penalty towards delayed supplies shall be to manufacturer’s account (if any).

1.33.1 The Employer may select transformer(s) from the supplied lot(s) at random for conducting the routine tests, at any test house(s) as mentioned above. The Bidder/manufacturer shall arrange these tests including loading, unloading and to & fro transportation up to the test house(s). The charges for such tests shall be reimbursable to the Bidder/manufacturer on actual basis on production of



documentary evidence in case the selected sample successfully withstands type test(s). In case of otherwise, no charges will be reimbursed.

1.33.2 Measurement of No Load Losses and Load Losses

(i) After pre-dispatch inspection of material at manufacturer’s works the transformers will be

subjected to the following test(s):

a) One transformer will be selected out of every lot of 25 Nos. or part thereof for measurement of No load Losses at rated voltage; No Load current (at 100% and 112.5% of rated voltage); Impedance voltage and Load Losses at rated current. The testing shall be arranged either at Employer’s own testing lab and / or at independent test lab. The testing charges for such tests shall be borne by the Employer. The test results will be applicable to the respective lot of 25 Nos. or part thereof from which sample was drawn. b) In case if dispatch instructions are less than 25 Nos. than one sample shall be selected from each store (s) and the test result so obtained shall be for the quantity consigned / received by the store (s).

1.34 GUARANTEE PERIOD: i) The defect liability period of plants/ equipments shall be as indicated in GCC 27 of Sec 7 and GCC 27.10 of Sec 8 of the bid document Vol. 1.35 ATTACHMENT DETAILS FOR TAMPER PROOF PROTECTION UNIT:

Tamper Proof Protection unit shall be manufactured in accordance with the following standards as given in drawing no/EZ-29 as given in Volume II.

The Enclosure Box shall comply with the requirement of I.S. 13947/I/1993 for Degree of Protection I.P.- 33. Three No. single pole MCCB shall be in accordance with I.S. 13947/II/1993 amended up to date.

General Technical Particulars:

The outdoor type distribution box is to be manufactured and supplied along with 3 No. SP MCCB with wiring in sheet steel cabinet duly powder coated. One no. LT post insulator for neutral connections shall be provided.

Protection Box: The Enclosure shall be fabricated by using CRCA sheet steel of not less than 16 SWG thickness & shall comply with the requirement of I.P. – 33 as per I.S. 13947/I/1993.

Box is to be provided with MCCB fixing arrangement such that front & back as well as up & down with tilting adjustment can be done to accommodate various type & make of MCCB. The box shall be provided to cover the LV bushing as shown in the drawing.

1.35.1 MAIN FEATURES OF THE PROTECTION BOX: The box shall be as per drawing no DISCOM/EZ-50 given in Volume II.

i) The single slide door panel shall be provided with slide opening. ii) Name plate iii) One door locking Patti (25x40 mm) provided with MIG welded for pad lock and sealing hole

arrangement. iv) Louvers are to be provided on both sides and in the bottom of MCCB Chamber. All louvers are

to be provided with fine wire mesh from inside. v) 2 Nos. earthing bolt size 25x10mm with 2 nos. washers and one nut are to be provided. vi) 2 Nos. Earth stickers or color embossing with Earth Symbol are to be provided. vii) 1 Nos. hole provided at bottom in Cable Gland Hole. All hole meant for cable entry / exit to be provided with rubber.



viii) 1 No. out coming terminal lug size 35 sq.mm to be provided. ix) Danger Plate 125x38mm with Hindi Language with “440V AC”. x) Flat Gasket of size 20x2mm is to be fixed with adhesive (fevibond) inside door. xi) All Hinges to be MIG Welded strictly. xii) All connecting wire ends should be fitted with proper lugs and properly connected except meter terminals. xiii) Single Panel Door. Pad lock of 6 levers to be supplied and welded on the door of make Harison/Jainson/Navtal.

NOTE: All dimensions are in MM.

Box Door – slide door opening. Sheet steel thickness: 2.0 mm (min) Paint shade: Exterior & Interior – D.A. Grey shade 632 of IS:5 Degree of enclosure protection IP:33 Cable entry at bottom as per drawing.

The size of box shown in mm. and may be more to suit the size of MCCBs. Drawing no DISCOM/EZ/ 50 covering the above aspects is given in Volume II.

General Arrangement of Chamber: General arrangement of chamber of the box shall be kept as per drawing covering the above aspects is given in drg. No DISCOM/EZ/ 50 given in Volume II. Single Pole MCCB of 40 Amps. shall be provided. The wiring from L.V. Terminals of Transformer to MCCB by 25 Sq.mm 4 Core Aluminum armoured cable.

The complete protection box shall be covered with single panel door and the panel door shall be sliding type, fittings shall be provided with a lock of ISI mark and with pad locking and sealing arrangement. 1.35.2 SPECIFICATION OF MCCB:

The following makes of MCCB shall be acceptable :- Seimens / L & T / ABB / GE Power / Schneider – France / SPACEAGE _Hyundai/ HAVELS. Single pole MCCB is to be provided on LV side for overload protection and magnetic trip release for instantaneous tripping in the wake of short-circuits. These MCCB’s shall be confirming to I.S. 13947/1993 as amended up to date. The rated un-interrupted current of MCCB shall be 40 Amp. The MCCB’s shall be manually independent & shall have quick make, quick break Mechanism, the detailed specification of MCCB shall be as under:

Application Outdoor (enclosed). Utilization category ‘A’ (IS: 13947/1993) as amended upto date. Type Thermal-Magnetic trip free mechanism. Number of poles Single Peak ambient temperature 50 °C. Rated insulation level 600 V. Rated operational voltage 433 V. Continuous current rating 40 A Ultimate Short Circuit Breaking capacity (ICU) 10 KA at 0.4 P.F. at 240 V AC. Rated service Short Circuit Breaking capacity (ICS) 10 KA at 0.4 P.F. at 240 V AC. Power factor for Short Circuit (max.) 0.4 (lag.) Application Standard IS 13947 Part-2 (latest) - 1993 Time current characteristics To co-ordinate with HV fuse.

The MCCB shall not cause any nuisance tripping due to switching current of motor & capacitor loads.

The Bidder shall submit the type test reports as per I.S. 13947/1993 for test sequence I,II & III complete with certified drawings, Oscillograms and approved drawing from NABL approved laboratory along with the offer.



The MCCB’s shall be marked with ‘Brand Name’ of manufacture and Ics in KA by embossing only whereas other particulars may be marked as per the manufacturers standard practice.

The contacts of MCCB should be self-wiping type so as to keep the contacts clean and milli-volt drop low. The MCCB shall be provided with push to trip facility.

The successful bidder shall be required to furnish the guarantee certificate of three (3) years

obtained from the MCCB manufacture. The liability of guarantee shall, however, be that of the bidder/contractor. If during the course of 36 months subsequent to the date of commissioning of MCCB, any of the goods is found to be defective in materials or workmanship or develops defects during service, the same shall be replaced / repaired by the bidder/contractor free of all charges. All necessary arrangements on this account will be made by the bidder/contractor. Acceptance Tests:

The following tests shall be carried out by the Employer’s representative on MCCB on the sample numbers equivalent to the number of transformer samples. 1. Overall Dimensional Checking. 2. High Voltage test at 3 kV for one minute. 3. Insulation resistance test. Instruction and operation Manual

The successful bidder shall be required to submit 5 copies of Instruction and Operation manual for each lot of 100 Transformers (or part thereof) supplied. This instruction manual should give complete details about the pre-commissioning tests/checks and 1.35.3 Signal Light (LED Indicating Lamp)

The MCCB enclosure shall be provided with LED indicating lamp (Three Nos.) to indicate tripping

of MCCB. An auxiliary relay with changeover contacts may be used to connect LED indicating lamp to the transformer secondary terminals if MCCB is not having auxiliary contacts. In case the MCCB trips or switched OFF, the relay contacts are closed which turns ON the LED indicating lamp. When the MCCB is reset and switched ON, the indicating lamp switches OFF. Signal light shall be arranged to avoid damages while handling the MCCB enclosure at site.

GUARANTEED TECHNICAL PARTICULARS FOR 25 KVA DISTRIBUTION TRANSFORMERS.

Sl. Particulars

No. 25 KVA (Al.wound)

1 Continuous Max. Rating (KVA)

2 Normal Ratio of Transformation 11/0.433 KV

3 Method of Connection (Vector Group) Dyn 11

4 Maximum temperature rise of winding by resistance

5 Maximum temperature rise of oil by thermometer

6 Flux Density 1.6 Wb/m2 (Max.)

7 Type of transformer Core type

8 CORE :

(a) Core Material & Grade

(b) No. of steps

(c) Dimensions of core steps

(d) Core diameter

(e) Core length (leg centre)

(f) Window height

(g) Insulation between bottom of core



Sl. Particulars


& Base channel

(h) Core height (inclusive of Base channel and insulation in between)

(i) Gross core area

(j) Effective core area

(k) Nos. & Dimensions of steel channel used for clamping of core

(l) Size & No.of :

(i) Core bolts

(ii) Tie rods

(m) Insulation of core bolts

(i) Core bolts

(ii) Tie rods

(n) Painting of core channel, Core bolts & Tie Rods

(o) Whether top yoke is cut or holes are made for LV connections. If yes, whether Enforcement is done.

(p) Size of support channel for core base cut channels are not acceptable).

(q) Weight of core only (without Channels etc.)

(r) Whether yoke construction is in one piece:

(a) Top

(ii) Bottom

9 Magnetizing current

(% of rated current):

(a) at 90% Voltage

(b) at 100% Voltage

(c) at 112.5% Voltage

(d) Tolerance

- As per Iss-

10 Current Density

(i) HV winding

(ii) LV winding



Sl. Particulars


11 WINDINGS

(a) Material

(iii) HV winding

(iv) LV winding

(b) Size of winding wires for

(i) H.T.

(ii) L.T.

(c) Type of insulation of

(i) HV winding

(ii) LV winding

(d) Internal & external

diameter of

(i) HV coil

(ii) LV coil

(e) No. coils/phase

(i) HV

(ii) LV

(f) No. of turns per coil

(i) HV

(ii) LV

(g) Method of connection of winding ends to bushing terminals:

(i) For HV - The one end of HV winding brazed with copper wire and other end of copper wire bolted with HV stud by forming eye loop and using washer of proper size.



Sl. Particulars


(ii) For LV-Other end of LV winding crimped with Aluminum/Copper lugs and then bolted with LV stud terminals with proper size of washers.

(iii) Method of forming of Star Connection:- All the three ends of LV windings crimped with proper size of Aluminum/copper lugs and then bolted with Aluminum/copper Flat of 6mm thick & cotton tape wrapped over it.

(h) Resistance/phase at 75ºC

(i) HV

(ii) LV

(i) Height of HV coil

(j) Wire used for delta formation:-

(i) Material

(ii) Diameter (Cross Sectional Area must be Min 1.5 time of Cross Section area of HV winding wire)

12 Fixed losses at normal ratio (KW) (Max.)

13 Load losses at normal ratio at 75oC (KW) (Max.)

14 Total losses at normal ratio (KW) (Max.)

15 Tolerance on losses at normal ratio.

16 Impedance voltage at normal ratio between

HV & LV windings at 75oC.

17 Impulse test level of HV & LV windings at 1.2/50

Micro second wave.

18 INSULATION OF MATERIAL:-

Insulation material used & its thickness:

a) Between core & LV

b) Spacers

c) Inter layer

d) Between HV & LV winding

e) Between phases

f) End insulation



Sl. Particulars


19 CLEARANCES:-

a) LV to Core (Radial)

b) Between HV & LV

(Radial)

c) Phase to phase

Between HV conductor (with providing min. of 2x1 mm Press Board to cover the tie rods)

d) Between winding & body

i) Length wise

ii) Breadth wise

e) End insulation

f) Thickness of locking spacers between HV coils

g) Axial wedges between HV & LV coils

h) Clearance between : (i) top cover and top of yoke

i) No. of radial spacers per phase between HV coil

g) Size of duct between LV & HV

SOURCE OF MATERIALS / PLACES OF MANUFACTURE, TESTING AND INSPECTION

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Sl.No. Item Source of Place of Place of testing

Material manufacture & inspection

- - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1. Lamination

2. Aluminum

3. Core plates

4. Steel castings

5. Tank

6. Radiators

7. Insulating cylinders

8. Insulating paper

9. Bushing HV/LV

10. Oil

11. Insulated winding wire

12. a) Tap changer

b) Thermometer

c) Pressure relief vent



A D D I T I O N A L D E T A I L S

SL.NO. DESCRIPTION

1. Core grade

2. Core diameter mm

3. Gross Core area sq cm

4. Net Core area sq cm

5. Flux density tesla

6. Wt. of the Core

7. Loss per kg. of core at )

the specified Flux Density )

8. Core window height

9. Centre to centre distance

10. No. of L.V.Turns

11. No. of H.V.Turns.

12. Size of L.V.Conductor bare covered (mm)

13. Size of H.V.Conductor bare covered (mm)

14. No. of parallels 15. Current density of L.V winding amps/mm2

16. Current density of H.V winding amps/mm2

17. Wt. Of the LV winding copper / Aluminum

18. Wt. Of the HV winding copper / Aluminum for Transformer Kg.

19. No. of LV coils / Phase

20. No. of HV coils/ Phase

21. Height of LV winding mm

22. Height of HV winding mm

23. ID/DD of LV winding mm

24. ID/DD of HV winding mm

25. Size of the duct in LV winding mm

26. Size of the duct in HV winding mm

27. Size of the duct between HV & LV mm

28. HV winding to LV clearance mm

29. HV winding to tank clearance mm

30. Calculated Impedance

31. HV to earth creep age distance

32. LV to earth creep age distance

DEPARTURE FROM SPECIFICATION

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Sl.No Reference to Clause No.

of this specification Departures.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- -



MANFACTURER’S AND PLACES OF MANUFACTURE TESTING & INSPECTION

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

S.No. Description Manufacturer Place of Place of testing

Manufacture & Inspection

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

WEIGHT AND DIMENSIONS OF PACKAGES OF DESPATCH

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Sl.No. Equipment Contents of Weight Dimensions

Individual Kg.

Packages

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

DESCRIPTIVE LITERATURE AND FULL PARTICULARS OF THE EQUIPMENT OFFERED

- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Sl.No. Item No. Description



2.0 TECHNICAL SPECIFICATION OF STEEL STRUCTURES AND SUPPORTS 2.1 SCOPE: 2.1.1 This specification calls for manufacture, stage testing, inspection and testing before dispatch,

packing and delivery of R.S. Joists, 175x85mm and 150x80mm. 2.1.2 The materials shall conform, in all respect, to the high standard of design and workmanship

and shall be capable of performing duties specified herein. Materials offered shall be complete in all respect.

2.2 STANDARDS:

Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable.

Sl No

Standard No Title

1 IS:2062 Grade `A’ Quality

Specification for R.S. Joists, M.S. Channels, M.S. Angles & M.S. Flats.

2 IS:2062 Chemical and physical composition of material 3 IS:1852 Rolling and cutting tolerances for Hot rolled steel products.

2.3 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS: In the paragraph 2.2 above relevant Indian standards specification have been mentioned.

However, the material meeting any other authoritative international standards, which ensures equal or better quality than the standards, mentioned shall also be acceptable. Material for which Indian Standards are not available, the relevant British standards and IEC recommendations will be applicable. Please attach photocopy of all such standards according to which the materials have been offered.

2.4 SERVICE CONDITIONS: 2.5 CLIMATIC CONDITIONS: The Steel Sections to be supplied against this specification shall be suitable for satisfactory

continuous operation under the following tropical conditions:-

1 Location At various substations in the State of Madhya Pradesh

2 Max. ambient air temperature 500C

3 Min. ambient air temperature 10C

4 Max. daily average ambient air temperature 400C 5 Max. yearly weighted average temperature 320C

6 Max. Relative Humidity 95% (Sometimes approaches saturation point)

7 Max. altitude above mean sea level 1000 Meters

8 Average Annual rainfall 125 cm

9 Max wind pressure 150 Kg/sq. meter

10 Isoceraunic level (Average Number of thunderstorm days per year)

50

11 Seismic level (Horizontal acceleration) 0.3g 2.6 LENGTH:- The materials to be supplied shall be in the following lengths: (i) R.S. Joists 175x85 mm 9 meters to 11 meters (ii) R.S. Joists 150x80 mm 1.5 meters

Any tolerance on negative or positive side shall not be accepted. 2.7 CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF R.S. JOISTS, CONFORMING

TO BE: 2062/84



C H E M I C A L C O M P O S I T I O N

CHEMICAL COMPOSITION FOR Fe 410 WA GRADE 1 C -- 0.23% MAX. 2 Mn -- 1.5% MAX. 3 S -- 0.050% MAX. 4 P -- 0.050% MAX. 5 SI -- 0.40% MAX. 6 CE

(Carbon Equivalent) -- 0.42% MAX.

2.8 M E C H A N I C A L P R O P E R T I E S 1. Tensile strength (min.) – 42 Kgf/mm2 or 410 N/mm2

2. Yield stress Min. for thickness/diameter

< 20 mm - 26 kgf/mm2 OR 250 N/mm2 20 – 40 mm - 24 kgf/mm2 OR 240 N/mm2 > 40 mm - 23 kgf/mm2 OR 230 N/mm2

3. Elongation %( min.) - 23% Bend test (internal Dia) - Min-3 t (t – is the thickness of the material) 2.8. MARKING:- It is desirable that the manufacture should put his identification marks on the finished

materials. The mark shall be in legible English letters given with marking dies of minimum 18 mm size at the

Interval of 3 meter mentioned as “ DISCOM-EZ”.. 2.9. INSPECTION AND TEST CERTIFICATE: The materials to be supplied will be subject to inspection and approval by the representative of

Employer. The Bidder is required to offer the finished material for inspection well in advance to the Employer.

The BILLETS/INGOTS from which materials shall be re-rolled and supplied to us shall be of

tested quality as per IS: 2830/6914 (Latest revision) respectively and shall be arranged from their own source. The chemical composition and physical properties of the finished materials shall be as per relevant specification indicated in Schedule-III enclosed.

The materials shall be tested in ISI approved Laboratory of the approved Manufacturer having

all facilities available for conducting all the tests as prescribed in relevant ISS. The Employer may get the material tested in the accredited laboratory by NABL. The testing charges whatsoever shall be to the Bidder’s account.

The Bidder is required to specifically indicate that the approved manufacturer:- (i) Holds valid ISI License against respective ISS. (ii) That the materials offered shall bear ISI certification marks.

(iii) Is required to submit a copy of the valid ISI License clearly indicating size and range of roll-able product against respective ISS.

2.10 GUARANTEED TECHNICAL PARTICULARS OF R.S Joists

Sr.No. Technical Particulars Particulars 1 Name of Manufacturer

& address

2 Chemical composition

3 Tensile strength



4 Yield stress

5 Elongation

6 Length in Meters

7 Dimension of cross section



3.0 GALVANIZED MILD STEEL CHANNEL, ANGLE AND FLAT This specification covers the manufacture, testing at works and supply of various sizes of mild

steel channels, angles & flats. The size of the channel, angle and flat normally used for Distribution transformers structures, 11 KV line structures and LT line structures are as follows;

i) Channel a) 100x50x6 mm b) 75x40x6 mm ii) Angle a) 50x50x6 mm b) 65x65x6 mm iii) Flat a) 50x6 mm The above list is merely indicative and not comprehensive. 3.1 APPLICABLE STANDADS The materials shall conform, in all respect, to the high standard of design and workmanship

and shall be capable of performing duties specified herein. Materials offered shall be complete in all respect.

3.1.1 STANDARDS: Materials shall conform to the latest applicable Indian standards. In case

bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable.

S No Standard No. Title 1 IS:2062 Grade ‘A’

Quality Specification for M.S. Angles, M.S. Channel and M.S. Flat

2 IS:2062-1969 Chemical and Physical composition of material 3 IS:1852-1985 Rolling and Cutting Tolerances for Hot Rolled Steel

products 3.1.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS: All relevant Indian standards

specifications have been mentioned. However, the material meeting any other authoritative international standards, which ensures equal or better quality than the standards, mentioned shall also be acceptable. Material for which Indian Standards are not available, the relevant British standards and IEC recommendations will be applicable. Please attach photocopy of all such standards according to which the materials have been offered.

3.2 RAW MATERIAL: The Steel Sections shall be re-rolled from the BILLETS/INGOTS of tested

quality as per latest version of IS:2830 or to any equivalent International Standard and shall be arranged by the contractor from their own sources. The Chemical composition and Physical properties of the finished materials shall be as per the relevant standards.

3.3 TEST: Steel Sections shall be tested in IS approved Laboratory or standard Laboratory of the

Bidder country having all facilities available for conducting all the tests as prescribed in relevant IS or IEC or to any equivalent International Standard or from any recognized and reputable International laboratory or Institutions.

The manufacture is required to specifically indicate that;

(i) They hold valid IS (or equivalent IEC) License. (ii) Steel Sections offered are bearing requisite IS certification or equivalent IEC marks.

The contractor are required to submit a copy of the valid IS (or equivalent IEC) License clearly indicating size and range of product against respective ISS or any equivalent International Standards along with their offer.

3.4 CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF M.S. ANGLES, M.S.

CHANNELS AND M.S. FLAT CONFORMING TO IS:2062-84

The mild steel shall conform to be: 2062 grade ‘a’ modified up to date or equivalent international standard for steel materials, documents for which shall be made available at the time of inspection to the board’s representative.



3.5 GENERAL REQUIREMENTS

The steel sections have chemical compositions and mechanical & properties confirming to IS:2062-1969 (latest revision).

3.6 All fabricated items shall be hot dipped galvanized as per IS: 2629-1985. The mass of zinc

coating and uniformity in thickness shall be determined as per relevant standards IS: 6745-1972 and IS: 2633-1986.

3.7 TOLERANCE: Variation in ordered quantity for any destination and over-all ordered quantity

shall be only to the extent of ± 2%. Rolling and weight tolerances shall be as per latest version of IS:1852 or to any equivalent International Standard.

3.8 MARKING: It is desirable that the manufacture should put his identification marks on the

finished materials. The mark shall be in “legible English letters” given with marking dies of minimum 18 mm size.

3.9 INSPECTION AND TEST CERTIFICATES: The materials to be supplied will be subject to

inspection and approval by the Employer’s representative before dispatch. Inspection before dispatch shall not, however, relieve the bidder of his responsibility to supply the steel structures strictly in accordance with the specification.

3.10 QUALITY ASSURANCE PLAN: 3.11 He Bidders must establish that the approved manufacturer is following a proper quality

assurance program for manufacture of steel sections.

3.12 All the fabricated structures shall be hot dipped galvanized. The galvanizing is to be done as per relevant IS specification. The galvanizing is to be done in such a way that it leaves smooth surface.

STEEL SECTION

NO. PARAMETERS UNIT VALUES Angle Channel Flat 1 Name and address of manufacture 2 Chemical composition FOR Fe 410 WA GRADE (Max) 1 C 0.23% MAX. 2 Mn 1.5% MAX. 3 S 0.050% MAX. 4 P 0.050% MAX. 5 SI 0.40% MAX. 6 CE

(Carbon Equivalent) 0.42% MAX.

3 Tensile strength 42.5 Kgf/mm2 or 410 N/mm2 4 Yield stress (For

Thickness/Diameter)

A Less than 20 mm 26 kgf/mm² OR 250 N/mm² B Between 20 to 40 mm 24 kgf/mm² OR 240 N/mm² C More than 40 mm 23 kgf/mm² OR 230 N/mm² 5 Elongation % 23% 6 Length in meters 7 to 13 meters 5.5 to 13

meters 5.5 to 13 meters

7 Dimension of cross section A 65x65x6 mm 100x50x6 mm

50x6 mm

8 Bend Test (Internal Dia) Min-3t (t – is the thickness of the material)



4.0 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS: 4.1 Service condition:

The polymer insulators to be supplied shall be suitable for satisfactory continuous operation under condition s as specified below:

(i) Maximum temperature of air in shed 45oC (ii) Minimum temperature of air in shed 4oC (iii) Maximum relative humidity 95% (The humidity

some time approaches saturation point)

(iv) Minimum relative humidity 10 % (v) Average number of dust-storm days per annum 40 days (vi) Average number of rainy days per annum 90 days (vii) Number of months of tropical monsoon

conditions per annum 3 months

(viii) Average annual rainfall 1250 mm (ix) Maximum wind pressure 150 Kg / Sq. mm (x) Altitude not exceeding 1000 meters (The limit of ambient temperature shall be 45oC peak and 35oC average over a period of 24 hours)

4.2 Composite insulators long rod type for tension locations: 4.2.1 The insulators shall be suitable for 3 phase, 50 Hz, effectively earthed 11 kV O/H distribution

system in a moderately polluted atmosphere. Long rod insulators shall be of tongue & clevis type.

4.2.2 Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,

projection etc, and selection in respect of polluted conditions shall be generally in accordance with the recommendation of IEC-60815/IS: 13134.

4.2.3 The size of Composite insulator, minimum creep age distance and mechanical strength along

with hardware fittings shall be as follows: SN Type of

composite Insulator

Nominal system voltage kV (rms)

Highest system voltage kV (rms)

Visible discharge test voltage kV(rms)

Wet power frequency withstand voltage kV (rms)

Impulse withstand voltage kV (rms)

Minimum creep age distance (mm)

Min. failing load KN

Pin ball shank dia meter (mm)

i. Long rod Insulators

11 12 9 35 75 240 45 16

Note: Creep age distances have been considered in line with IS-13134 (which specifies 20mm/ kV for

moderately polluted environment). 4.3 Dimensional Tolerance of Composite Insulators:-

The tolerances on all dimensions e.g. diameter, length and creep age distance shall be allowed as follows in line with-lEC 61109: ± {0,04d+1.5) mm when d<300 mm, ± (0.025d-r-6J mm when d>3GQ mm. Where, d being the dimensions in millimeters for diameter, length or creep age distance as the case may be,

However, no negative tolerance shall be applicable to creep age distance.

4.4 Interchangeably:-

The composite Insulators including the end fitting connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant IEC/IS standards.

4.5 Corona and Rl Performance:-



All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and not generate any radio interference be end specified limit under the operating conditions.

4.6 Maintenance:- 4.6.1 The composite Insulators offered shall be suitable for use of hot line maintenance technique

so that usual hot line operation can be carried out with ease, speed and safety. 4.7 BASIC FEATURES 4.7.1 Design and construction:

The composite insulator shall have a core, housing & weather shed of insulating material and steel/aluminum alloy hardware components for attaching it to the support/conductor.

4.7.2 Core:

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and resin shall be optimized in the FRP rod. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured through Pollution process. The FRP rod shall be void free.

4.7.3 Housing (Sheath):

The FRP rod shall be covered by a seamless sheath of a silicone electrometric compound or silicone alloy compound of a thickness of 3mm minimum.

It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core and shall have chemical bonding with the FRP rod. The strength of the bond shall be greater than the tearing strength of the polymer. Sheath material in the bulk as well as in the sealing/bonding shall be free from voids.

4.7.4 Weather sheds:

The composite polymer weather sheds made of silicone electrometric compound or silicon alloy shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath and shall be free from imperfections. The weather sheds should have silicon content of minimum 30% by weight. The strength of the weather shed to sheath interface shall be greater than the tearing strength of the polymer. The interface, if any, between sheds and sheath (housing] shall be free from voids.

4.7.5 End Fittings:

End fittings transmit the mechanical load to the core. They shall be made of spheroidal graphite cast Iron, malleable cast iron or forged steel or aluminum alloy. They shall be connected to the rod by means of a controlled compression technique. The gap between fitting and sheath shall be sealed by a flexible silicone electrometric compound or silicone alloy compound sealant. System of attachment of end fitting to the rod shall provide superior sealing performance between housing, i.e. seamless sheath and metal connection. The sealing must be moisture proof.

The dimensions of end fittings of Insulators shall be in accordance with the standard dimensions stated in IS: 2486 / IEC: 60120.

4.8 WORKMANSHIP:

4.8.1 All the materials shall be of latest design and conform to the best engineering practices

adopted in the high voltage field. Bidders shall offer only such Insulators as are guaranteed by them to be satisfactory and suitable for continued good service in power transmission lines.

4.8.2 The design, manufacturing process and material control at various stages shall be such as to

give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and corners.

4.8.3 The design of the Insulators shall be such that stresses due to expansion and contraction in

any part of the insulator shall not lead to deterioration. 4.8.4 The core shall be sound and free of cracks and voids that may adversely affect the Insulators.



4.8.5 Weather sheds shall be uniform in quality. They shall be clean, sound, and smooth and shall

be free from defects and excessive flashing at parting lines. 4.8.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings

should be effectively sealed to prevent moisture ingress; effectiveness of sealing system must be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with out projecting points or irregularities, which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly.

4.8.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc

equivalent to 610 gm/Sq.m, or 87µ m thickness and shall be in accordance with the requirement of IS: 4759, The zinc used for galvanizing shall be of purity 99.5% as per IS: 4699, The zinc coating shall be uniform, adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains, bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least four successive dips each lasting for one H) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining.

4.9 EQUIPMENT MARKING: 4.9.1 Each insulator unit shall be legibly and indelibly embossed/engraved with the following details

as per IEC-61109:

(a) Month &Year of manufacture (b) Min. failing toad/guaranteed mechanical strength in kilo Newton followed by

the word 'KN' to facilitate easy identification. (c) Manufacturer’s name/Trade mark

4.9.2 One 10mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the

end fitting of each composite long rod of particular strength in case of 33 kV Insulators for easy identification in case both types of Insulators are procured by the utility. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark:

For 45 kN long rod unit : Blue For 70 kN long rod unit : Red (Not applicable)

4.10 DRAWINGS: 4.10.1 The Contractor shall furnish full description and illustration of the material offered. 4.10.2 The Contractor shall furnish along with the proposal outline drawing (3 copies) of each

insulator unit including a cross sectional view of the long rod insulator unit. The drawing shall include but not be limited to the following information:

(a) Long rod diameter with manufacturing tolerances (b) Minimum Creep age distance with positive tolerance (c) Protected creep age distance (d) Eccentricity of the long rod unit

(i) Axial run out (ii) Radial run out

(e) Unit mechanical and electrical characteristics (f) Size and weight tongue & clevis (g) Weight of composite long rod unit. (h) Materials

(i) Identification mark (ii) Manufacturer's catalogue number

4.10.3 The contractor shall submit full dimensioned manufacturing insulator drawings containing all

the details in four (4) copies along with copies of all the type tests. 4.11 TESTS AND STANDARDS:

Insulators offered shall be manufactured with the same configuration & raw materials as used in the Insulators for which design & type test reports are submitted. The manufacturer shall



submit a certificate for the same. The design & type test reports submitted shall not be more than 05 years old.

4.11.1 Design tests:

Manufacturer should submit test reports for Design Tests as per IEC - 61109 (clause - 5) along with the bid. Additionally following tests shall be carried out or reports for the tests shall be submitted after award of contract: + UV test: The test shall be carried out in line with clause 7.2 of ANSI C29.13

4.11.2 Type Tests:

The following type tests shall be conducted on a suitable number of individual insulator units, components, materials or complete strings:

4.11.3 The Bidder shall submit type test reports as per IEC 61109 along with the bid. Additional type

tests as required below shall be carried out by the manufacturer, after SN Description of type test Ten procedure/standard

1. Dry lightning impulse withstand voltage test As per IEC 61109 (clause 6.1)

2. Wet power frequency test Ai per IEC 61 109 (clause 6,2)

3. ,.

Mechanical load-time test As per IEC 61 109 (clause 6 4)

4. Radio interference test As per IEC 61109 (clause 6.4)

5. Recovery of Hydrophobicity test

6. Chemical composition test for silicon content

7. Brittle fracture resistance test

4.11.4 It shall be the option of the Employer to accept the Insulators based on type test reports submitted by the Bidder/ approved manufacturer. The Employer may get type test done in the presence of their authorized representative. 4.11.5 All the type test given in Clause No. 8.2 in addition to routine & acceptance test shall be

carried out on insulator along with hardware fittings wherever required. 4.12 Acceptance (sample) Tests 4.12.1 For Composite Insulators

(a) Verification of dimensions : Clause 7.2 IEC: 61109,

(b) Verification of the locking system applicable

: Clause 7.3 IEC: 61 109

(c) Galvanizing test : IS:2633/IS:6745

(d) Verification of the specified mechanical load : Clause 7.4 IEC: 611 09,

4.13 Routine Tests:

sn Description Standard

1 Identification of marking As per IEC: 61 109 Clause 8.1

2 Visual Inspection As per IEC 61 109 Clause 8.2

3 Mechanical routine test As per IEC: 61 109 Clause 8.3

4.14 Tests during Manufacture



Following tests shall also be carried out on all components as applicable a) Chemical analysis of zinc used for galvanizing b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for

malleable castings. c) Chemical analysis, hardness tests and magnetic particle inspection for forgings. 4.15 Sample Batch for Type Testing 4.15.1 The contractor shall offer material for sample selection for type testing only after getting Quality

Assurance Programme approved by the Owner, The contractor shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample foe type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Employer.

4.16 Additional Tests: 4.16.1 The Employer reserves the right to get any other test(s) of reasonable nature carried out at

Bidder/manufacturer's premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to ensure that the material complies with the specifications.

4.16.2 The Employer also reserves the right to conduct ail the tests mentioned in this specification at

his own expense on the samples drawn from the site at Bidder/manufacturer's premises or at any other test center. In case of evidence of non compliance, it shall be binding on the part of the Bidder/manufacturer to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies or replacement of defective items, all without any extra cost to the Owner,

4.17 Co-ordination for Testing: 4.17.1 The Bidder/manufacturer shall have to co-ordinate testing of Insulators with hardware fittings

to be supplied by other Bidder/manufacturer and shall have to guarantee overall satisfactory performance of the Insulators with the hardware fittings.

4.18 Quality assurance plan: 4.19 The successful contractor shall submit information as per details in Part A of specification. . 4.20 Guarantee:

The Bidder/manufacturer of Insulators shall guarantee overall satisfactory performance of the insulators for the period as mentioned in clause 27.2 of Sec 7 – GCC.

4.21 Test Reports:- 4.21.1 At least three copies of type test reports shall be furnished. One copy shall be returned duly

certified by the employer, only after which the commercial production of the concerned material shall start

4.21.2 Record of routine test reports shall be maintained by the Bidder/manufacturer at hi^ works for

periodic inspection by the Owner's representative. 4.21.3 Test certificates of test during manufacture shall be maintained by the Bidder/manufacturer.

These shall be produced for verification as and when desired by the Owner. 4.22 INSPECTION: 4.22.1 The material for final inspection shall be offered by the Bidder/manufacturer only under packed

condition. The employer shall select samples at random from the packed lot for carrying out acceptance tests. The lot offered for inspection shall be homogeneous and shall contain Insulators manufactured in 3-4 consecutive weeks.

4.22.2 No material shall be dispatched from its point of manufacture before it has been satisfactorily

inspected and tested unless the inspection is waived off by the employer in writing. In the later case also the material shall be dispatched only after satisfactory testing specified herein has been completed.

4.23 PACKING: 4.23.1 Al I Insulators shall be packed in strong corrugated box of min, 7 ply duly paletted or wooden

crates. The gross weight of the crates along with the material shall not normally exceed 100 Kg



to avoid handling problem. The crates shall be suitable for outdoor storage under wet climate during rainy season.

4.23.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at

site and subsequent handling in the field. 4.23.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent

damage or deformation during transit and handling. 4.23.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their

destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each wooden case/crate/corrugated box shall have all the markings stenciled on it in indelible ink.

4.23.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at

site. 4.24 Tests on Insulator Units 4.24.1 RIV Test (Dry):-

The insulator string along with complete hardware fittings shall have a radio interference voltage level below 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10 kV& 30 kV for 11 kV& 33 kV class insulators respectively under dry condition. The test procedure shall be in accordance with IS:326B /I EC : 437/CISPfi 18-2.

4.24.2 Brittle Fracture Resistance Test:-

Brittle fracture test shall be carried out on naked rod along with end fittings by applying "1 n HNO3 acid" (63 g cone, HN03 added to 937 g water) to the rod. The rod should be held at 80% of SML for the duration of the test. The rod should not fail within the 96 hour test duration. Test arrangement should ensure continuous wetting of the rod with Nitric acid.

4.24.3 Recovery of Hydrophobicity & Corona test:-

The test shall be carried out on 4mm thick samples of 5cm x 7cm i) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the

surface to dry and spray with water Record the Hydrophobicity classification in line with STRI guide for Hydrophobicity classification.. Dry the sample surface.

ii) The sample shah subjected to mechanical stress by bending the sample over a

ground electrode. Corona is continuously generated by applying 12 kV to a needle like electrode placed 1mm above the sample surface. The test shall be done for 100 hrs.

iii) Immediately after the corona treatment, spray the surface with water and record the

HC classification. Dry the surface and repeat the corona treatment as at clause 7 above. Note HC classification. Repeat the cycle for 1000 hrs. Or until an HC of 6 or 7 is obtained. Dry the sample surface.

iv) Allow the sample to recover and repeat hydrophobiticiy measurement at several lime

intervals. Silicone rubber should recover to HC 1 - HC 2 within 24 to 48 hours, depending on the material and the intensity of the corona treatment.

4.24.4 Chemical composition test for Silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test may be carried out at CPRI or any other NABL accredited laboratory.

GUARANTEED TECHNICAL PARTICULARS OF 11 KV 45 KN, COMPOSITE POLYMER INSULATORS LONG ROD TYPE) SUITABLE FOR T&C TYPE HARDWARES

Sl. No.

Description 11KV, 45 KN

1. Name of Manufacturer 2. Address:

(a) registered Office (b) Factory



Sl. No.

Description 11KV, 45 KN

3. Type of Insulators 4. Standard specification to which the Insulators manufactured

and tested

5. Name of material used in manufacture of the Insulator (with class / grade)

(a) Material of core rod (b) Material of Housing & weather sheds (silicon content by weight)

(c) Material of end fittings : tongue/clevis

(d) Sealing compound for end fitting 6. Color Glaze of Insulator

7. Electrical Characteristics:

(a) Nominal system Voltage (KV rms)

(b) Highest System Voltage (KV rms)

(c) Dry power frequency withstand (KV rms)

(d) Wet power frequency withstand (KV rms)

(e) Dry flash over voltage (KV rms)

(f) Wet flash over voltage (KV rms)

(g) Dry lighting impulse withstand voltage

(a) Positive

(b) Negative

(h) Dry lighting impulse flashover voltage

(a) Positive (KV peak)

(b) Negative (KV peak)

(i) RIV at 1 MHz when energized at 10kV/30kV (rms) under dry condition (microvolt)

(j) Creep age distance (min) mm

8.

Mechanical Characteristics:

Minimum failing load (KN)

9. Dimensions of Insulator: i. Weight (Kg.) ii. Dia of FRP rod (mm) iii. Length of ERP rod (mm) iv. Dia of weather sheds (mm) v. Thickness of housing (mm) vi. Dry arc distance (mm) 10. Dimensioned drawings of Insulator (including weight with tolerances in weight)

enclosed.

11. Method of fixing of sheds to housing specify ):- single mould or modular construction (injection molding/compression molding)

12. No. of weather sheds 13. Type of sheds

(i) Aerodynamic (ii) With under ribs

14. Packing details (a) Type of packing. (b) No. of Insulators in each pack (c ) Gross weight of package

15. Any other particulars which the bidder may like to give.



5.0 STRAIN HARDWARE FITTINGS 11KV DISC INSULATORS

(FOR 11 KV LINES SUITABLE FOR USE WITH TONGUE & CLEVIS DISC INSULATORS (CONVENTTIONAL TYPE FITTINGS)

5.1 TYPE TEST CERTIFICATE The following shall constitute the type tests for clamps.

1. Visual examination 2. Verification of dimensions 3. Slip strength tests 4. Ultimate strength tests 5. Galvanizing/Electroplating tests.

The type tests are intended to prove the general qualities and design of a given type of insulator fittings. These tests should have not been conducted earlier, than 5 years from the date of opening of tender.

5.2 ACCEPTANCE TESTS The following shall constitute the acceptance tests:-

1. Visual examination tests 2. Verification of dimensions 3. Galvanizing/electroplating test 4. Mechanical Tests 5. Ultimate Strength test

5.3 ROUTINE TESTS The following shall constitute the routine tests:-

1. Visual examination tests 2. Mechanical routine tests on Conductor Tension clamp only 3. The routine tests will be carried out on each of insulator fittings to check requirement which are

likely to vary during production.

All the above three tests have been described in IS:2486 (Part-I)-1993. Galvanizing tests for Hot Dip ferrous material shall be carried out in accordance with IS:2633-1986 and satisfy the requirements in IS:4759-1984. Electro-galvanized ferrous fittings shall be checked in accordance with IS:1573-1986. However one Sample from each lot will be tested as per IS:4759-1984.

(A) 11KV STRAIN HARDWARE FITTINGS (T&C) TYPE

Each Hardware fittings of the Strain insulators shall comprise of:- Hot dip galvanized cross arms & straps, properly profiled and suitable for use on 75/100 mm channel cross arms with 16mm dia hot dip galvanized Bolts, Nuts, Spring, Washers, Plain washer and 4mm dia split pin as per figures 26 of IS:2486 (Part-II)- 1984 and its latest amendment: Spoil type clamp with clevis eye suitable for 11KV system for following sizes of AAA conductors:-

S. No.

Item Stranding and Wire Dia of A.A. Alloy

Actual Area

i AAA Conductor (Rabbit)

(7/3.15mm) 55 Sq. mm

Iii AAA Conductor (Panther)

(7/3.81mm) 200 Sq. mm



The ultimate strength of the clamp should not be less than 4500 Kg. The Clamp shall be made by process of Die-casting. The clamp made with process of sand casting shall not be accepted. All dimensions of cleaves and tongue connections shall be as per figure-25 of the IS: 286 (Part-II) -1989 and its latest amendments.

5.4 GENERAL REQUIREMENTS

All fittings shall be of same type and design manufactured under similar conditions of production. All forging and castings shall be of good finish and free from flaws and other defects. The edges on the outside of fittings, such as the eye, clevis and holes, shall be rounded. The clamp shall be manufactured by the process of die casting or pressure die casting and shall be free from blow holes and other defects.

All ferrous fittings and the part other than those of stainless steel shall be galvanized by the Hot Dip process. Only small fittings like, plain & spring washers, nuts may be electroplated galvanized. The nuts shall conform to property 4.8 of IS:1367 (Part-6)-1980. The collar pins shall be provided with Galvanized Mild Steel Flat Washers in addition to split pins. The split pin to be used on the collar pin shall be of phosphor bronze conforming to IS:7814-1975 or Stainless Steel conforming to IS:5577-1992 or brass conforming to IS:410-1977 with a minimum hardness of 160 HV.

5.5 MARKING ON CLAMPS

The clamps shall have the following markings for their identification as per ISS. Trade Mark of manufacturer Please note that the marking should be legible and permanent (preferable die caste).

5.6 PACKING

Strain clamps and related hardware shall be packed in double gunny bags or wooden cases if deemed necessary. The gross weight of the packing shall not exceed 50 Kg. Different fittings shall be packed in different bags or cases and shall be complete with minor accessories fitted in place. All the nuts shall be hand tightened over the bolt and screwed upto the farthest point with split pin in position. The packing shall be fit to withstand rough handling during transit and storage at destination.

5.7 CLAMPS & CONNECTORS 5.7.1 Clamps & connectors shall conform to IS:5561. The clamps and connectors shall be made of

materials listed below:

For connecting AAA conductors

Aluminum alloy casting, conforming to designation A6 of IS:617 and shall be tested for all tests as per IS: 617

For connecting equipment terminals made of copper with AAA conductor

Bimetallic connectors made from Aluminum alloy casting conforming to designation A6 of IS:617 with 2mm thick Bimetallic liner and shall be tested as per IS:617

For connecting GS shield wire

Galvanized mild steel

Bolts, Nuts & plain washers Hot dip galvanized mild steel for sizes M12 and above, and electro-galvanized for sizes below M12

Spring washers for items ‘a’ to ‘c’

Electro-galvanized mild steel suitable for at Least service condition 4 as per IS:1573-1986.



All castings shall be free from blowholes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. No current carrying part of a clamp or connector shall be less than 10 mm thick. They shall be designed and manufactured to have minimum contact resistance.

For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided. Flexible connectors, braids or laminated strips made up of copper/ aluminum for the terminal clamps for equipment shall be suitable for both expansion or through (fixed/ sliding) type connection of IPS Aluminum tube as required. In both the cases, the clamp height (top of the mounting pad to center line of the tube) should be same. Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e. indelibly marked) on each components of the clamp/ connector, except on the hardware. Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less than that of the conductor at the specified ambient temperature. The rated current, for which the clamp/ connector is designed with respect to the specified reference ambient temperature, shall also be indelibly marked on each component of the clamp/connector, except on the hardware. Clamps and connector shall be designed corona controlled. Clamps & connectors shall conform to type tests and shall be subjected to routine and acceptance tests on minimum 3 samples per lot as per IS:5561. Type tests report for all clamps and connectors for temperature rise test, the Contractor shall furnish tensile test.

GTP of 11KV ALLUMINIUM ALLOY STRAIN HARDWARE FITTINGS (T&C) TYPE

Sl. Particulars

Requirement To be specified

A Whether clevis and tongue parts are according to figure 25 of IS-2486 (Part-2) 1989 and its latest amendments

B Whether cross arm straps with 16mm dia bolt are according to figure 26 of IS-2486 (Part-2) 1989 and its latest amendments

D No. of Spring washer and its thickness suitable for the quoted items

E Ultimate Strength (Kgs.) 3000 Kg (Min.) F Materials for clamp High strength

aluminum alloy.

G For galvanizing whether zinc conforms to grade Zn 98 of IS 209-1966 and galvanizing of ferrous material is done in accordance with the IS: 2633: 1986 and satisfied the requirements in IS: 4759-1984

H Weight of complete unit (Kgs.) I Process for casing the clamps (Die / Pressure) Die casting



6.0 TECHNICAL SPECIFICATION FOR COMPOSITE POLYMER

PIN INSULATORS FOR USE IN 11KV and 33KV SYSTEM

1.0 SCOPE::

This specification covers design, manufacture, testing and supply of Composite Polymer Pin Insulators

for use in the 11KV & 33KV overhead transmission lines. The Composite Pin Insulators shall be of the

following type:-

i) Long rod type Pin Insulators intended to be mounted rigidly on a supporting structure to support

following size of conductor:-

(a) For 11KV AAAC Rabbit

(b) For 33KV AAAC Dog

2.0 APPLICABLE STANDARDS::

2.1 Standards:-

Following Indian/International Standards, which shall mean latest revision, with amendments/changes

adopted and published, unless specifically stated otherwise in the Specification, shall be referred while

accessing conformity of Insulators with these specifications.

2.1.1 In the event of supply of Insulators conforming to standards other than specified, the Bidder shall

confirm in his bid that these standards are equivalent or better to those specified. In case of award,

salient features of comparison between the standards proposed by the Bidder and those specified in

this document will be provided by the Supplier to establish equivalence.

Sl.

No.

Indian Standard

Standard

Title International

Standard

1 Definition, test methods and acceptance criteria for composite Insulators for

a. c. overhead lines above 1000V.

IEC:61109

2 IS: 731 Porcelain insulators for overhead power lines with a nominal voltage greater

than 1000V.

IEC: 60383

3 IS:2071 Methods of High Voltage Testing. IEC:60060-1

4 IS:2486 Specification for Insulator fittings for overhead power lines with a nominal

voltage greater than 1000V General Requirements and Tests Dimensional

Requirements locking devices.

IEC:60120

IEC:60372

5 - Thermal Mechanical performance test and mechanical performance test on

string Insulators units.

IEC:60575

6 IS: 13134 Guide for the selection of insulators in respect of polluted condition. IEC: 60815

7 - Characteristics of string insulator units of the long rod type. IEC: 60433

8 - Hydrophobicity Classification Guide. STRI guide 1.92/1

9 - Radio interference characteristics of overhead power lines and high voltage

equipment.

CISPR 18.2 Part 2

10 IS:8263 Methods of RI Test of HV Insulators. IEC:60437

11 Standard for Insulators- Composite- Distribution Dead-end Type. ANSI C 29.13-2000

12 IS:4759 Hot dip zinc coatings on structural steel & other allied products. ISO:1459

13 IS:2629 Recommended practice for Hot Dip galvanization for iron and steel ISO:1461(E)

14 IS:6745 Determination of weight of zinc coating on zinc coated Iron and steel articles. ISO:1460

15 IS:3203 Methods of testing of local thickness of electroplated coatings. ISO:2178

16 IS:2633 Testing of Uniformity of coating of zinc coated articles.

17 - Standard specification for glass fiber standards. ASTM D

578-05

18 - Standard specification for compositional analysis by Thermo-gravimetery. ASTM D

578-05

19 IS:4699 Specification for refined secondary zinc

3.0 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS::

3.1 Service condition:-

The polymer Insulators to be supplied shall be suitable for satisfactory continuous operation under

condition s as specified below:



(i) Maximum temperature of air in shed 45oC

(ii) Minimum temperature of air in shed 4oC

(iii) Maximum relative humidity 95% (The humidity some time

approaches saturation point)

(iv) Minimum relative humidity 10 %

(v) Average number of dust-storm days per annum 40 days

(vi) Average number of rainy days per annum 90 days

(vii) Number of months of tropical monsoon conditions per annum 3 months

(viii) Average annual rainfall 1250 mm

(ix) Maximum wind pressure 150 Kg / Sq. mm

(x) Altitude not exceeding 1000 metres

(The limit of ambient temperature shall be 45oC peak and 35oC average over a period of 24 hours)

3.2 Composite Insulators long rod type to support conductor on 11KV & 33KV Over head Power

Lines:-

3.2.1 The Insulators shall be suitable for 3 Φ, 50 Hz, effectively earthed 1IkV and 33kV O/H distribution

system in a moderately polluted atmosphere.

3.2.2 Bidder must be an indigenous manufacturer and supplier of composite Insulators of rating 11KV or

above OR must have developed proven in house technology and manufacturing process for composite

Insulators of above rating OR possess technical collaboration/ association with a manufacturer of

composite Insulators of rating 11KV or above. The Bidder shall furnish necessary evidence in support

of the above along with the bid, which can be in the form of certification from the utilities concerned, or

any other documents to the satisfaction of the owner.

3.2.3 Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,

projection etc, and selection in respect of polluted conditions shall be generally in accordance with the

recommendation of IEC-60815/IS: 13134.

3.2.4 The size of Composite insulator, minimum creepage distance and mechanical strength along with

hardware fittings shall be as follows:

SN Type of

composite

Insulator

Nominal

system

voltage kV

(rms)

Highest

system

voltage

kV (rms)

Visible

discharge

test voltage

kV(rms)

Wet power

frequency

withstand

voltage kV

(rms)

Impulse

withstand

voltage kV

(rms)

Minimum

creepage

distance

(mm)

Min.

failing

load KN

i. 11KV Pin

Insulator

11 12 9 35 75 320 5

ii. 33KV Pin

Insulator

33 36 27 75 170 900 10

Note: Creepage distances have been considered in line with IS-13134 (which specifies 20mm/ kV for moderately polluted environment and 25mm/KV for heavily polluted area)

3.3 Dimensional Tolerance of Composite Insulators :-

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows

in line with IEC 61109:

± {0.04d+1.5) mm when d<300 mm,

± (0.025d+6J mm when d>300 mm.

Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case may

be,

However, no negative tolerance shall be applicable to creepage distance.

3.4 Corona and Rl Performance:-

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part

shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and

manufactured that it shall avoid local corona formation and not generate any radio interference beyond

specified limit under the operating conditions.



4.0 BASIC FEATURES:: 4.1 Design and construction:-

The Composite Pin Insulator shall have a core, housing & weather shed of insulating material and

steel/aluminum alloy hardware components for attaching it to the support/conductor.

4.1.1 Core:-

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass

fibers and resin shall be optimized in the FRP rod. Glass fibers shall be Boron free

electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high

electrical integrity and high resistance to acid corrosion. The matrix of

the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured through Pultrusion

process. The FRP rod shall be void free.

4.1.2 Housing (Sheath):-

The FRP rod shall be covered by a seamless sheath of a silicone elastomeric compound or silicone

alloy compound of a thickness of 3mm minimum. It shall be one-piece housing using Injection

Molding Principle to cover the core. The elastomer housing shall be designed to provide the

necessary creepage distance and protection against environmental influences. Housing shall conform to

the requirements of IEC 61109/92-93 with latest amendments.

4.1.3 Weather sheds:-

The composite polymer weather sheds made of a silicone elastomeric compound or silicone alloy

compound shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath

and shall be free from imperfections It should protect the FRP rod against environmental influences,

external pollution and humidity. The weather sheds should have silicon content of minimum 30% by

weight. The strength of the weather shed to sheath interface shall be greater than the tearing strength of

the polymer. The interface, if any, between sheds and sheath (housing) shall be free from voids.

4.1.4 End Fittings:-

End fittings transmit the mechanical load to the core. They shall be made of spheroidal graphite cast

Iron, malleable cast iron or forged steel or aluminum alloy. They shall be connected to the rod by means

of a controlled compression technique. The material used in fittings shall be corrosion resistant. As the

main duty of the end fittings is the transfer of mechanical loads to the core the fittings should be properly

attached to the core by a coaxial or hexagonal compression process & should not damage the individual

fibers or crack the core. The gap between fitting and sheath shall be sealed by a flexible silicone

electrometric compound or silicone alloy compound sealant. System of attachment of end fitting to the

rod shall provide superior sealing performance between housing, i.e. seamless sheath and metal

connection. The sealing must be moisture proof.

The dimensions of end fittings of Insulators has been shown in the drawing (11KV & 33KV both

separately). Since we are purchasing these items for the first time, the drawing given is for indicative purpose.

The details of end fittings for fixing the same with V-Cross Arms and top clamps are given below:-

Sl.

No.

Item Length of end fittings to

be fixed

Min. threaded portion of end

fittings

Dia of rod

i. 11KV 150 mm 100 mm 20 mm

ii. 33KV 150 mm 100 mm 24 mm

Upper end fittings shall be suitable to hold AAAC Dog for 33KV and AAAC Rabbit for

11KV. The size of the fittings shall be in such a way that conductor could be bound firmly so that it

may not slip from the groove while in service even under adverse conditions.

5.0 WORKMANSHIP::

5.1 All the materials shall be of latest design and conform to the best engineering practices adopted in the

high voltage field. Bidders shall offer only such Insulators as are guaranteed by them to be satisfactory

and suitable for continued good service in power transmission lines.

5.2 The design, manufacturing process and material control at various stages shall be such as to give

maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of

sharp edges and corners.



5.3 The design of the Insulators shall be such that stresses due to expansion and contraction in any part of the

insulator shall not lead to deterioration.

5.4 The core shall be sound and free of cracks and voids that may adversely affect the Insulators.

5.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free from

defects and excessive flashing at parting lines.

5.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should be

effectively sealed to prevent moisture ingress; effectiveness of sealing system must be supported by test

documents. All surfaces of the metal parts shall be perfectly smooth with out projecting points or

irregularities, which may cause corona. All load bearing surfaces shall be smooth and uniform so as to

distribute the loading stresses uniformly.

5.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to

610 gm/Sq.m, or 87µ m thickness and shall be in accordance with the requirement of IS: 4759, The zinc

used for galvanizing shall be of purity 99.5% as per IS: 4699. The zinc coating shall be uniform,

adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains,

bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least

four successive dips each lasting for one H) minute duration under the standard preece test. The

galvanizing shall be carried out only after any machining.

6.0 EQUIPMENT MARKING::

6.1 Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-61109:

(b) Month &Year of manufacture

(b) Min. failing toad/guaranteed mechanical strength in kilo Newton followed by

the word 'KN' to facilitate easy identification.

(c) Manufacturer’s name/Trade mark

7.0 BID DRAWINGS::

7.1 The Bidder shall furnish full description and illustration of the material offered.

7.2 The Bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit including a

cross sectional view of the long rod insulator unit. The drawing shall include but not be limited to the

following information:

(a) Long rod diameter with manufacturing tolerances

(b) Minimum Creepage distance with positive tolerance

(c) Protected creepage distance

(d) Eccentricity of the long rod unit

(i) Axial run out

(ii) Radial run out

(e) Unit mechanical and electrical characteristics

(f) Weight of composite long rod unit.

(g) Materials

(i) Identification mark

(ii) Manufacturer's catalogue number

7.3 After placement of award, the Supplier shall submit three sets of full dimensioned

manufacturing insulator drawings containing all the details to The Chief Engineer

(FS-EZ), MPPKVVCL, Jabalpur.

7.4 After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for

different type of Insulators for approval of the owner.

8.0 TESTS AND STANDARDS:: Insulators offered shall be manufactured with the same configuration & raw materials as used in the

Insulators for which design & type test reports are submitted. The manufacturer shall submit a

certificate for the same. The design & type test reports submitted shall not be more than 05 years old.

8.1 Design Tests:-

For polymeric insulators it is essential to carry out design test as per clause 4.1 of IEC 61109 / 92-93

with latest amendments. The design tests are intended to verify the suitability of the design, materials

and method of manufacture (technology). When a composite insulator is subjected to the design tests,



the result shall be considered valid for the whole class of insulators, which are represented by the one

tested and having the following characteristics:

• Same materials for the core, and sheds and same manufacturing method;

• Same material of the fittings, the same design, the same method of attachment;

• Same or greater layer thickness of the shed material over the core (including a

sheath where used);

• Same or smaller ratio of the highest system voltage to insulation length;

• Same or smaller ratio of all mechanical loads to the smallest core diameter

between fittings

• Same or greater diameter of the core.

The tested composite insulators shall be identified by a drawing giving all the dimensions with

the manufacturing tolerances.

Manufacturer should submit test reports for Design Tests as per IEC-61109 (clause- 5) along

with the bid. Additionally following tests shall be carried out or reports for the tests shall be submitted

after award of contract: UV test: the test shall be carried out in line with clause 7.2 of ANSI C29.13.

8.2 Type Tests:-

The tenderer shall furnish detailed type test reports of the offered composite Insulators as per clause

8.2 of the Technical Specifications at the NABL approved laboratories to prove that the composite

Insulators offered meet the requirements of the specification. These Type Tests should have been carried

out within five years prior to the date of opening of this tender. The following type tests shall be

conducted on a suitable number of individual insulator units, components & materials and the test report

should invariably be submitted with the bid:-

SN Description of type test Ten procedure/standard

1. Dry lightning impulse withstand voltage test As per IEC 61109 (clause 6.1)

2. Wet power frequency test As per IEC 61 109 (clause 6,2)

3. Mechanical failing load test As per IS:731 (Clause- 10.8.2)

4. Radio interference test As per IEC 61109 (clause 6.4)

5. Recovery of Hydrophobicity test Annexure-A

This test may be repealed every 3 yrs by

the manufacturer

6. Chemical composition test for silicon content Annexure-A

Or any other test method acceptable to the

owner

7. Brittle fracture resistance test Annexure - A

Note:- The purchase may like to conduct any other test(s) in addition to above tests at bidder’s cost to

establish the performance of material as per system requirement.

8.2.2 It shall be the option of the owner to accept the Insulators based on type test reports submitted by the

manufacturer. The owner shall be free to repeat the type test & may witness the same.

Note: The owner, for the purpose of facilitating the type tests, may ask the bidders to quote test charges separately

8.2.3 All the type test given in Clause No. 8.2 in addition to routine & acceptance test shall be carried out on

Pin Insulators wherever required.

8.3 Acceptance (sample) Tests

a. Verification of dimensions Clause 7.2 IEC: 61109

b. Verification of the locking system (if applicable) Clause 7.3 IEC: 61 109

c. Galvanizing test IS:2633/IS:6745

c. Verification of tightness of the interface between end fittings &

Insulator housing

Clause 7.4 IEC:61109

amendment 1 of 1995

d. Verification of the specified mechanical load Clause 7.4 IEC: 611 09 / IS:731

The test samples after having withstood the routine test shall be subjected to the following



acceptance tests:-

Routine Tests:-

SN Description Standard

1. Identification of marking As per IEC: 61 109 Clause 8.1

2. Visual Inspection As per IEC 61 109 Clause 8.2

3. Mechanical routine test As per IEC:61109 / IS:731

8.5 Tests during Manufacture

Following tests shall also be carried out on all components as applicable:-

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable

castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable

castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

8.6 Additional Tests:-

8.6.1 The Owner reserves the right at his own expenses, for carrying out any other test(s) of reasonable nature

carried out at Supplier's premises, at site, or in any other place in addition to the aforesaid type,

acceptance and routine tests to satisfy himself that the material comply with the Specifications.

8.6.2 The Owner also reserves the right to conduct all the tests mentioned in this specification at his own

expense on the samples drawn from the site at Supplier's premises or at any other test center. In case of

evidence of non compliance, it shall be binding on the part of the Supplier to prove the compliance of

the items to the technical specifications by repeat tests or correction of deficiencies or replacement of

defective items, all without any extra cost to the Owner,

9.0 Quality assurance plan:- 9.1 The successful bidder shall submit following information to the owner:

9.1.1 Test certificates of the raw materials and bought out accessories.

9.1.2 Statement giving list of important raw materials, their grades along with names of sub-suppliers for raw

materials, fist of standards according to which the raw materials are tested. List of tests normally carried

out on raw materials in presence of bidder's representative.

9.1.2 List of manufacturing facilities available.

9.1.3 Level of automation achieved and lists of areas where manual processing exists.

9.1.4 List of areas in manufacturing process, where stage inspections are normally carried out for quality

control and details of such tests and inspections.

9.1.5 List of testing equipments available with the bidder for final testing of equipment along with valid

calibration reports.

9.1.6 The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same shall be

followed during manufacture and testing,

9.1.7 The successful bidder shall submit the routine test certificates of bought out raw materials / accessories

and central excise passes for raw material at the time of inspection.

10.0 Guarantee:-

The Supplier of Insulators shall guarantee overall satisfactory performance of the Insulators for the

period of 18 months from the date of supply.

11.0 INSPECTION:: 11.1 The owner's representative shall at all times be entitled to have access to the works and all places of

manufacture, where insulator, and its component parts shall be



manufactured and the representatives shall have full facilities for unrestricted

inspection of the Supplier's and sub-Supplier's works, raw materials, manufacture

of the material and for conducting necessary test as detailed herein.

11.2. The material for final inspection shall be offered by the Supplier only under packed condition. The

owner shall select samples at random from the packed lot for carrying out acceptance tests. The lot

offered for inspection shall be homogeneous and shall contain Insulators manufactured in 3-4

consecutive weeks.

11.3 The Supplier shall keep the Owner informed in advance of the time of starting and the progress of

manufacture of material in their various stages so that arrangements could be made for inspection.

11. 4 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected

and tested unless the inspection is waived off by the owner in writing. In the later case also the material

shall be dispatched only after satisfactory testing specified herein has been completed.

11.5 The acceptance of any quantity of material shall in no way relieve the Supplier of his responsibility for

meeting all the requirements of the specification and shall not prevent subsequent rejection, if such

materials are later found to be defective.

12.0 PACKING:: 12.1 All Insulators shall be packed in strong corrugated box of min, 7 ply duly paletted or wooden crates. The

gross weight of the crates along with the material shall not normally exceed 100 Kg to avoid handling

problem. The crates shall be suitable for outdoor storage under wet climate during rainy season.

12.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and

subsequent handling in the field.

12.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or

deformation during transit and handling.

12.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination

and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and

faulty or illegible markings. Each wooden case/crate/corrugated box shall have all the markings

stenciled on it in indelible ink.

12.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at site.

Tests on Insulator Units

Annexure-A

1 RIV Test (Dry):-

The insulator string along with complete hardware fittings shall have a radio interference voltage level

below 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10 kV& 30 kV for 11 kV&

33 kV class insulators respectively under dry condition. The test procedure shall be in accordance with

IS:326B/IEC : 437/CISPfi 18-2.

2 Brittle Fracture Resistance Test:- Brittle fracture test shall be carried out on naked rod along with end fittings by applying "1 n HNO3

acid" (63 g cone, HN03 added to 937 g water) to the rod. The rod should be held at 80% of SML for the

duration of the test. The rod should not fail within the 96 hour test duration. Test arrangement should

ensure continuous wetting of the rod with Nitric acid.

3 Recovery of Hydrophobicity & Corona test:-

The test shall be carried out on 4mm thick samples of 5cm x 7cm

ii) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface to

dry and spray with water Record the Hydrophobicity classification in line with STRI guide for

Hydrophobicity classification.. Dry the sample surface.

ii) The sample shall be subjected to mechanical stress by bending the sample over a ground

electrode. Corona is continuously generated by applying 12 kV to a needle like electrode

placed 1mm above the sample surface. The test shall be done for 100 hrs.



iii) Immediately after the corona treatment, spray the surface with water and record the HC

classification. Dry the surface and repeat the corona treatment as at clause 7 above. Note HC

classification. Repeat the cycle for 1000 hrs. or until an HC of 6 or 7 is obtained. Dry the

sample surface.

iv) Allow the sample to recover and repeat hydrophobiticiy measurement at several lime intervals.

Silicone rubber should recover to HC 1 - HC 2 within 24 to 48 hours, depending on the

material and the intensity of the corona treatment.

4 Chemical composition test for Silicon content The content of silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X-ray)

Analysis or Thermo-gravimetric analysis. The test may be carried out at CPRI or any other NABL

accredited laboratory.



Annexure-B

GUARANTEED TECHNICAL PARTICULARS OF 11KV & 33KV COMPOSITE POLYMER PIN

INSULATORS

(To be filled and kept in envelops containing Technical Offer)

Sl.

No.

Description 11KV

33KV

1. Name of Manufacturer

2. Address:

(a) registered Office

(b) Factory

3. Type of Insulators

4. Standard specification to which the Insulators manufactured

and tested

5. Name of material used in manufacture of the Insulator

(with class / grade)

(a) Material of core rod

(b) Material of Housing & weather sheds (silicon content by weight)

(c) Material of end fittings : tongue/clevis

(d) Sealing compound for end fitting

6. Colour Glaze of Insulator

7. Electrical Characteristics:

(a) Nominal system Voltage (KV rms)

(b) Highest System Voltage (KV rms)

(c) Dry power frequency withstand (KV rms)

(d) Wet power frequency withstand (KV rms)

(e) Dry flash over voltage (KV rms)

(f) Wet flash over voltage (KV rms)

(g) Dry lighting impulse withstand voltage

(a) Positive

(b) Negative

(h) Dry lighting impulse flashover voltage

(a) Positive (KV peak)

(b) Negative (KV peak)

(i) RIV at 1 MHz when energized at 10kV/30kV (rms) under dry condition (microvolt)

(j) Creepage distance (min) mm

8.

Mechanical Characteristics:

Minimum failing load (KN)

9. Dimensions of Insulator:

i. Weight (Kg.)

ii. Dia of FRP rod (mm)

iii. Length of ERP rod (mm)

iv. Dia of weather sheds (mm)

v. Thickness of housing (mm)

vi. Dry arc distance (mm)

10. Dimensioned drawings of Insulator (including weight with tolerances in weight) enclosed.

11. Method of fixing of sheds to housing specify ):- single mould or modular construction

(injection moulding/compression moulding)

12. No. of weather sheds

13. Type of sheds

(i) Aerodynamic



Sl.

No.

Description 11KV

33KV

(ii) With under ribs

14. Packing details

(a) Type of packing.

(b) No. of Insulators in each pack

(c ) Gross weight of package

15. Any other particulars which the bidder may like to give.



Sl. No. 7 (GS Pin for 11KV Pin insulator is deleted



8.0 TECHNICAL SPECIFICATION OF 9KV GAPLESS POLYMER

LIGHTENING ARRESTORS

1. SCOPE: This specification covers design manufacture assembly, testing at manufacturers works supply and delivery of single phase outdoor metal oxide Polymeric housed distribution type gapless surge arresters for use in effectively earthed system with the transformer neutral effectively earthed with normal voltage of 11 KV for 9 KV Lightning arrestors. The rated voltage of Arrestors shall be 9KV (rms) for 11 KV system. 2. CLIMATIC CONDITIONS:-

(i) Location In the State of Madhya Pradesh, India.

(ii) Maximum Ambiant Air Température Deg. C 50 (iii) Minimum Ambiant Air Température Deg. C 2 (iv) Average Daily Ambient Air Temperature Deg. C 32 (v) Maximum Relative humidity (%) 90 (vi) Average rainfall per annum (mm) 1200 (vii) Maximum Altitude above mean sea level (meters) Not more than 1000 meters

(Average 200 to 600 Mtrs) (viii) Isoceraunic level (Day/annum) 20/50 (ix) Maximum Wind Pressure (kg/sq.meters) 45 (x) Seismic level (Horizontal acceleration) 0.1 g 3. SPECIAL CONDITIONS:- The atmosphere at places is laden with dust in suspension during the dry months and subject to fog in cold months. The temperature variation between the daily minimum and maximum is large. Heavy lightning is usual in the area during the month of May to November. The area is also subjected to heavy monsoon rains 80% to 90% of the annual participation during the months of June to October. 4. SYSTEM CONDITIONS:-

(i) Nominal system voltage 11KV (ii) Highest system voltage 12KV

(iii) Frequency 50 Hz

(iv) Fault level 250MVA

4.1 The system is 3 phase 50 Hz solidly grounded system with earth fault protection. The winding

of transformer, which is to be protected, is connected in delta formation. 4.2 We will place one set of surge arresters at the entry of the each line (feeder) in the substation

and one set near to the transformers for 33KV system & only one set each on 11 KV Distribution transformer.

4.3 The insulation level provided in our transformer is 170KVp for 33KV System and in case of 11KV

System, 75KVp. 5. STANDARD:- The surge arresters shall strictly conform to IEC 60099-4 /IS-3070 Part-3 - 1993 with latest amendment if any in all respects. Maximum residual voltage shall comply with the requirement given hereunder:- The surge arresters meeting any other authoritative standards, which ensure equal or better performance than mentioned above, shall be acceptable. 6. The technical requirement have been detailed out below: 6.1 The supplier should offer nearest rating of surge arresters. 6.2 The transformers, which are to be protected having BIL 170 KVp for 33KV winding & 75 KVp for

11KV winding. We will be installing our LAs at a distance of 5/10 meters from transformer (another 5 meters be added towards height of LAs lead length and bushing of



transformers). Considering 20% safe margin as per IEC the impulse voltage of more than 136 KVp should not appear across the 33 side of transformer. Similarly, impulse voltage of more than 60 KVp should not appear across 11KV winding of transformer.

6.3 Required Technical particulars:

S.No. Particulars Requirements 1. Nominal system voltage 9KV 2. Type of Arrestor Gap-less

(Metal Oxide) 3. Applicable Standard IEC 60099-4

IS 3070 Part-III latest Amendment.

4. Rated Arrestor voltage KV rms 9 5. Maximum continuous operating

voltage KVrms 7.2

6. Nominal discharge current rating (8/20 micro sec) KA

5.0

7. Minimum discharge capability (KJ/KV)

NA

8 Long duration discharge class NA 9. Maximum residual voltage at nominal

discharge current of 8/20 micro sec. wave, KV peak

32

10. Maximum steep current impulse residual voltage at nominal discharge current, KV Peak

38

11. Maximum switching impulse residual voltage at 500 Amp. (Peak)

NA

12. Minimum prospective symmetrical current (KA)

15

13. Impulse high current short duration discharge of 4/10 micro sec. wave (KAP)

65

14. Max. radio interference voltage at 1000 Hz (micro volts)

--

15. Overall temporary over voltage withstand capacity (KVrms)

a) 1.0 Sec.

10

b) 10.0 Sec.

9.5

c) 100.0 Sec.

-

16. Impulse withstand voltage (KVP) 75 17. Current impulse withstand level 18 impulse

of long duration Current 200 Amp

peak for 2000 micro secs. As per IEC 99/4

18. Pressure relief device N.A.

19. Disconnecting device As per required specification IEC 99

20. Min. creepage distance of porcelain housing (mm)

300

21. Terminal arrangement Built in clamping Type, can be adjusted for Horizontal & Vertical take off to suit

conductor Size squirrel to raccoon. 22. Earthing Terminal The base of L.A. shall be provided with

two separate terminal / distinctly marked for connection to earth



6.4 Residual voltage for 8/20 micro sec. wave of nominal discharge current KA are specified above, however, we will prefer still lower residual voltage to ensure better protection.

6.5 The requirement of energy is very specific based on our system. The firms are requested to offer

nearest energy rating of LAs for both single and double shot. 6.6 Current impulse withstands level - The 9KV arrestors shall withstand 18 impulse of long

duration current with a peak level of 200 Amp. & duration 2000 micro secs. 7.1 DISCONNECTING DEVICE: - The arrestor for 9 KV system be provided with a suitable disconnecting device. This shall be

connected in series with the ground lead and should not effect the sealing system of the arrestor. The disconnecting device shall conform to the requirement specified in IS:3070 (Part-II)1993 & IEC 99 - 4 (1991-II) clause 5.12, 7.6.3.

7.2 A surge arrester having one or several non-linear metal-oxide resistors with highly non-linear

voltage-current characteristics, connected in series, but having no integrated series or parallel spark gaps.

7.3 A surge arrester with a housing made of polymeric material without air voids neither between

the housing and the metal-oxide resistors nor the housing itself. The surge Arrester housing shall be made with silicone Rubber (polymeric) of reputed manufacturer. The Silicone rubber used for housing should pass the tracking & erosion test of 4.5kv as per IEC 587.The surge arrester should be made without any internal gas volume.

The adhesion between the polymeric housing and the metal-oxide resistors or any other metallic or non-metalic parts inside the housing must be strong enough, homogeneous, robust and resistant to thermal cycles and environmental stresses.

7.4 All the units of arresters of same rating shall be interchangeable type without adversely affecting

the performance. 7.5 All necessary bolts, nuts clamps etc., required for mounting on support structure shall be included

in the scope of supply. 7.7 The polymer material which is used for the arrester housing must be tracking and erosion

resistant, stabilized against UV radiation and have proven records in similar applications (like MV/HV cable terminations, insulators and arresters) in country.

7.8 All exposed ferrous parts shall be hot dip galvanized as per IS:2633. 7.9 Line terminal pads and ground terminal pads should be hot dip galvanized. 8. TERMINAL CONNECTORS:- Terminal connectors shall be manufactured and tested as per IS:5361 and should be type

tested. The terminal connector drawings should be submitted separately with the tender documents.

8.1 All casting shall be free from blow holes, surface blisters, crakes and cavities. All sharp edges

and corners shall be blurred and rounded off. 8.2 All current carrying parts shall be designed and manufactured to have minimum contact

resistance. 8.3 The contact surface must be machined smooth to obviate excessive current density. 8.4 The terminal connector for connection of conductor should be suitable for ACSR Squirrel

to Raccoon conductor with Universal take off arrangement (can be adjusted for both horizontal & vertical take off) and should have adequate current carrying capacity.

8.5 The terminal connector shall be manufactured out of Aluminum alloy grade LM 9 or 25 as per

IS and by gravity die casting process only. 8.6 The base of the Polymer Lightning Arrestor shall be provided with two separate terminal

distinctly marked for connection to earth.



9. NAME PLATE: The arresters shall be provided with non-corrosive legible name plate fitted rigidly at arrestor body with indelibly marked with the following information :- (i) PD [FS] MPMKVVCL, BHOPAL (ii) Order No. & date. (iii) Manufacturer’s name or trade mark and identification Serial Number of the

arrester. (iv) Rated voltage. (v) Maximum continuous operating voltage. (vi) Type (vii) Rated frequency (viii) Nominal discharge current (ix) Long duration discharge class (x) Rated Short Circuit current . (xi) B.I.L. of the equipment to be protected (xii) Year of manufacture The nameplate should be fitted rigidly so that during life of arrestor, there should not be any possibility of removal of name plate. 10. DRAWINGS:- The supplier shall furnish two sets of following drawings for our approval before commencing the supplies:-

i) General outlines drawings of the complete arrester with technical parameters. ii) Drawings showing clearance from grounded and other live objects and between adjacent poles

of surge arresters required at various heights of surge arresters. iii) Mounting clamp details of surge arresters. iv) Details of the terminal and ground terminals. v) Volt time characteristics of surge arresters. vi) The detailed dimensional drawing of polymeric housing such as ID, OD, thickness and

insulator details such as height, profile of petticoats angle of inclination and gap between successive petticoats total creep age distance etc.

11. TESTS & TEST CERTIFICATES:

11.1 Type Test Certificates :- The complete type test certificate from Govt. approved laboratories i.e. CPRI, NFL, NTL, ERDA etc. for the LAs of all the types/rating as per IEC 99/4 /IS 3070 (Part III) shall compulsorily be submitted in support of evidence of compliance of the specifications & guaranteed particulars. It should cover all the type tests as prescribed in Clause 7.1 of IEC 99/4 and IS-3070 (Part-III).

Note:- Type test report of manufacturer’s laboratory shall not be acceptable. 11.2 TYPE TESTS:- (A) The following type tests shall be made in accordance with Clause 7.1 of IEC 99/4/IS-3070 Part-III

latest amendment:-

1. Insulation withstand test. 2. Residual voltage test 3. Long duration current impulse withstand test 4. Operating duty test 5. Test of Arrestor Dis-connectors (for 9 KV LAs) 6. Partial discharge test. 7. Accelerated ageing test 8. Power frequency voltage versus time characteristic.



(B) The following additional tests are to be also made 1. Moisture ingress test 2. Weather aging test 3. Galvanising test on steel metal parts

(C) For energy calculation, set of type test reports should be submitted. 11.3 ACCEPTANCE TESTS: The following tests as per clause 8.2 of IEC 99/4 and IS-3070 Part-I & Part-II shall be done on the lower whole number of the cube root of the number of arresters to be supplied.

a) Power frequency reference voltage test at reference current on complete arresters.

b) Lightning impulse residual voltage test at nominal discharge current on complete arresters. c) Partial discharge test.

d) Galvanizing test on exposed steel parts.

e) Visual/dimensional examination.

11.4 ROUTINE TESTS:- The following routine tests as per Clause 8.1 of IEC 99/4 / IS-3070 Part-1/Part-III are to be conducted by the manufacturer on offered lot for pre-despatch inspection. The lot offered without routine test reports shall not be considered & delay in acceptance of the offer will be on firm’s account:-

a) Measurement of the reference voltage on the complete arresters. b) Residual voltage test at nominal discharge current on the complete arresters or sections. c) Test to verify the efficacy of sealing. d) Partial discharge test

12. INSPECTION:- 12.1 The purchaser’s representative shall at all times be entitled to have access to the works and all

places of manufacture where equipment/material shall be manufactured and the representative shall have full facilities for unrestricted inspection of the supplier’s works raw materials and process of manufacture for conducting necessary tests as detailed herein.

12.2 The supplier shall keep the purchaser informed in advance of the time of starting and of the

progress of manufacture of equipment/material in its various stages so that arrangements can be made for inspection.

12.3 No material shall be dispatched from its point of manufacture before it has been satisfactorily

inspected and tested, unless the inspection is waived off by the purchaser in writing. In the later case also, the equipment/material shall be dispatched only after satisfactory testing for all tests specified herein has been completed.

12.4 The acceptance of any quantity of material shall in no way relieve the supplier of any of his

responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective.

12.5 The number of sample selected to carry out the acceptance test shall be as per provision in

the respective IS. 12.6. The purchaser has the right to have the tests carried out by an independent Agency subject

to recovery of testing expenditure in case of failure, whenever there is dispute regarding the quality of supply.

GUARANTEED TEHCNICAL PARTICUARS OF 9KV POLYMER LIGHTNING ARRESTERS

Sr. No.

Particulars 9 KV LA

1 Name of manufacturer & place of manufacture



Sr. No.

Particulars 9 KV LA

2 Type

3 Model

4 Applicable standard

5 No. of units (no.)

6 Rated voltage (KV rms)

7 Rated frequency (Hz)

8 Maximum continuous operating voltage (KV r m s)

9 Maximum leakage current at continuous operating voltage (micro Amps)

10 Temporary power frequency over voltage capacity (KV rms)

(a) For 0.1 sec.

(b) For 1 sec.

(c) For 10 secs.

(d) For 100 secs.

11 Nominal discharge current (KA)(8/20 micro sec wave)

12 Energy class

13 Minimum discharge capability (KJ/KV)

(a) For single impulse energy

(b) For 2 consecutive discharge with 50/60 sec. between them

14 Maximum Switching Serge protection level at 500A

15 Maximum equivalent front of wave protection level (KVp)

16

(a) 5 KA

(b) 10 KA

(c) 20 KA

17 Maximum steep current Impulse residual voltage at nominal discharge current(KVP)

18 Maximum switching impulse Residual voltage at 500 Amp. Peak

19 Minimum prospective symmetrical current (KA)

20 Impulse high current short duration discharge of 4/10 Micro sec wave (KAP).

21 Long duration current impulse withstand :

(a) Current peak (Amps.)

(b) Virtual duration (Micro sec.)

22 Maximum radio interference voltage at 100 KHz (micro volts/DB)

23 Pressure relief device capability (Short circuit capability)

(a) High current (Amps.)

(b) Low current (Amps.) +

24 Protective ratio (RDV/BIL)

25 Total creepage distance mm

26 Impulse withstand voltage Kvp.

27 Reference current (MAP)

28 Partial discharge i.e. PICO

29 Power frequency withstand voltage of arrestor Housing (KVrms)

(a) Dry

(b) Wet

30 Lightning impulse withstand voltage of arrestor housing (KVP)

31 Current impulse withstand level

32 Type of dis-connective device

33 Dimensions of Arrestor :

(a) Max. dia (mm)

(b) Complete height of arrestor (mm) from base to line side(mm)

(c) Total creepage of distance of arrestor housing (mm)



Sr. No.

Particulars 9 KV LA

(d) Net weight of each arrestor (Kg)

34 Construction of arrester

(a) Material of valve

(b) Details of sealing

(c) Description of pressure relief system

(d) No. of unit per arrester

35 Type & Dimensions of clamping bracket

36 Material of Top & Bottom metal cap.

37 Type of terminal arrangement (Whether as per tender Specification)

38 Size of line/ground terminals

39 Minimum recommended spacing between Centre to centre of LA. (mm)

40 Clearance required from ground equipment at various heights of arrester units. (mm)

41 Earthing arrangement provided for earthing side of arrester (whether as per our requirement)



9.0 11 KV ISOLATORS 9.1 SCOPE This specification provides for design, manufacture, testing at manufactures works, delivery of

outdoor station type 11KV (Local) manual operating mechanism isolating complete in all respect with bi-metallic connectors. Operating mechanism, fixing details etc. shall be as described herein.

9.2 PARTICULARS OF THE SYSTEM The isolators to be provided under this specification are intended to be used on 3 phase AC 50

cycles, effectively grounded system. The nominal system voltages are 11 KV. 9.3 STANDARD The isolator shall comply in all respects with IS: 9921 or IEC Publication No: 129. Equipment

meeting any other authoritative standard which ensures an equal or better quality than the standard mentioned above will also be accepted.

9.4 TYPE & RATING 9.4.1 Isolators shall have three posts per phase, triple pole single throw, gang operated out-door

type silver plated contacts with horizontal operating blade and isolators posts arranged vertically. The isolators will be double break type. Rotating blade feature with pressure relieving contacts is necessary i.e. the isolator shall be described in detail along-with the offer. However, the design of turn & twist arrangement shall be subject to employer’s approval. (Banging type feature is not acceptable). All isolators shall operate through 90 degree from their fully closed position to fully open position, so that the break is distinct and clearly visible from the ground level.

9.4.2 The equipment offered by the contractor shall be designed for a normal current rating of 630

amps for 11 KV suitable for continuous service at the system voltage specified herein. The isolators are not required to operate under load but they must be called upon to handle magnetization currents of the power transformers and capacitive currents of bushings, bus-bars connections, very short lengths of cables and current of voltage transformers.

9.4.3 The rated insulation strength of the equipment shall not be lower than the levels specified in IS

9921 JEC publication No. 129, which are reproduced below

Standard declared voltage kv/rms

Rated voltage of the Isolator

Standard withstand positive Kv (peak)

Impulse Voltage polarity

One minute power frequency withstand voltage KV (RMS)

Across the isolating distance

To earth and between poles

Across the isolating distance

To earth and between poles

11 KV 12 85 75 45 35 9.4.4 The 11 KV isolators are required with post insulators but without mounting structures. The

isolators should be suitable for mounting on the Boards standard structures. The isolators shall be supplied with base channels along with fixing nuts, bolts and washers for mounting on the structured.

9.4.5 TEMPRATURE RISE

The maximum temperature attained by any part of the equipment when in service at site under continues full load conditions and exposed to the direct rays of Sun shall not exceed 45 degree centigrade above ambient temperature.



9.6 ISOLATOR INSULATION Isolation to ground, insulation between open contacts and the insulation between phases of

the completely assembled isolating switches shall be capable of withstanding the dielectric test voltage specified above.

9.7 MAIN CONTACTS 9.7.1 All isolators shall have heavy duty self aligning and high pressure line type fixed contacts of

modern design and made of hard drawn electrolytic copper. The fixed contact should be of reverse loop type. The various parts shall be accordingly finished to ensure interchangeability of similar components.

9.7.2 The fingers of fixed contacts shall be preferably in two pieces and each shall form the reverse

loops to hold fixed contacts. The fixed contacts would be placed in ‘c’ clamp. The thickness of ‘C’ clamp shall be adequate. This channel shall be placed on a channel of adequate thickness. This channel shall be welded on an insulator mounting plate of 8mm thickness. The spring of fixed contact shall have housing to hold in place. This spring shall be made of stainless steel with adequate thickness. The pad for connection of terminal connector shall be of aluminum with thickness not less than 12 mm.

9.7.3 The switch blades forming the moving contacts shall be made from tubular section of hard

drawn electrolytic copper having outer dia not less then 38 mm and thickness 3 mm. These contacts shall be liberally dimensioned so as to withstand safely the highest short circuit and over voltage that may be encountered during service. The surfaces of the contacts shall be rendered smooth and silver plated. The thickness of silver plating shall not be less than 15 microns for 11 KV. In nut shell, the male and female contact assemblies shall be of robust construction and design of these assemblies shall ensure the same.

1. Electro-dynamic withstands ability during short circuit without any risk of repulsion of contacts. 2. The current density in the copper parts shall not be less than 2 Amp/sq.mm and Aluminum

parts shall be less than 1 Amp/sq.mm. 3. Thermal withstand ability during short circuit. 4. Constant contact pressure even when the live parts of the insulator stacks are subjected to

tensile stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature verification or strong winds.

5. Wiping action during closing and opening. 6. Self alignment assuring closing of the switch without minute adjustment.

9.8 CONNECTORS 9.8.1 The connectors for 11KV isolator shall be made of Aluminum alloy LM-9 or LM-25 and shall be

suitable for ACSR Panther Conductors for 11KV with horizontal and vertical take off arrangement. The details in regard to dimensions, the number of bolts to be provided, material and manufacture shall be furnished by the bidder for Employer approval before manufacturing. The groove provided in the connection should be able to accommodate conductor size mentioned above smoothly.

9.8.2 The design of clamps shall be to the Employer for approval. The clamps to be offered should be manufactured by gravity die-casting method only and not by sand casting process. It is necessary that suitable clamps are offered along with the isolator and also it is obligatory to give complete technical particular of clamps along with the drawing, as per details given above and also as per following detail.

1. The terminal connector shall be manufactured and tested as per IS: 5561. 2. All castings shall be free from blow holes, surface blisters, cracks and cavities. 3. All the sharp edges shall be blurred and rounded off. 4. No part of the clamp shall be less than 12 mm thick. 5. All current carrying parts shall be designed and manufactured to have minimum contact

resistance. 6. Connectors shall be designed to be corona free in accordance with the requirement of IS:

5561. 7. All nuts and bolts shall be made of stainless steel only. Bimetallic sleeve/liner shall be 2 mm

thick



Wherever necessary, bi-metallic strip of standard quality and adequate dimension shall be used.

9.9. POST INSULATOR

11KV insulators shall be of reputed make subject to employer approval. The post insulators for the above 11 KV isolators shall comprise of three numbers 11 KV insulators per stack and 9 such stack shall be supplied with each isolator. The insulator stack shall conform to the latest applicable Indian or IEC standard and in particulars to the IS; 2544 specification for porcelain post insulators. The porcelain used for manufactures of insulators shall be homogeneous, free from flaws or imperfections that might affect the mechanical or dielectric quality, and they shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be uniform brown color, free from glisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts should be assembled in such a manner that any thermal expansion differential between the metal and the porcelain parts throughout the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly bdispatch. The cap and base of the insulators shall be interchangeable with each other. The contractor shall furnish with the offer technical guaranteed particulars of insulators offered by them. Please note that isolators without type test certificates will not be accepted.

9.9.1 Each 11KV Insulators used in the isolators should have technical particulars as detailed below:-

11KV 1. Nominal system voltage KV (rms) 11 2. Highest system voltage KV (rms) 12 3. Dry P.F. One minute with stand KV (rms) 35 4. Wet PF one minute withstand KV (rms) 35 5. P.F. Puncture withstand test voltage KV 1.3 time the actual dry flash

over voltage of the unit. 6. Impulse voltage withstand test KV (peak) 75 7. Visible discharge test KV voltage 9 8. Creep age distance mm (min) 320 9. Tensile strength in KN 10KN 9.9.2 Operating Mechanism for 11KV Isolators:-

All Isolators shall have separate dependent manual operation. The Isolator should be provided with padlocking arrangements for locking in both end position to avoid unintentional operation. For this purpose Godrej make 5 lever brass padlocks having high neck with three keys shall be provided. The isolating distances should be visible for isolators.

The Isolators and Isolators inclusive of their operating mechanism should be such that they cannot come out of their open or close position by gravity wind pressure, vibrations reasonable shocks or accidental touching of connecting rods of the operating mechanism. Isolators should be capable of resisting in closed position, the dynamic and thermal effects of maximum possible short circuit current at the installation point. They shall be so constructed that they do not open under the influence of the short circuit current. The operating mechanism should be of robust construction and easy to operate by a single person and conveniently located for local operation in the switchyard. Provision for earthing of operating handle by means of 8 SWG GS wire must be made.

9.10 PIPES

Tandem pipes operating handle shall be class B ISI marked type having at least 24mm internal diameter for 11KV/33KV isolator. The operating pipe shall also be class B ISI marked with internal diameter of at least 32 mm for 11 KV isolators.

The pipe shall be terminated in to suitable universal type joints between the insulator bottom bearing and operating mechanism.



9.11 BASE CHANNEL

The Isolator shall be mounted on base fabricated from steel channel section of adequate size not less than 75x40x6 mm for 11KV . To withstand total weight of isolator and insulator and also all the forces that may encounter by the isolator during services, suitable holes shall be provided on this base channel to facilitate it’s mounting on our standard structures. The steel channel in each phase shall be mounted in vertical position and over it two mounting plates at least 8mm thick with suitable nuts and bolts shall be provided for minor adjustment at site.

9.12 CLEARANCES We have adopted the following minimum clearance for isolators in our system .The bidder should therefore keep the same in view while submitting their offers: -

Description Center distance between Poles

(Center to Center) i.e. Phase to Phase clearance

Distance between center lines of outer posts on same pole

11 KV Isolator 75 Cm 60 Cm GTP of 11 KV ISOLATORS

No Particular Requirement To be specified

1. Type, make and country of origin

i Make ii Type 2 Maximum permissible continuos service voltage (KV) 12 KV 3 Clearance in air (minimum) a Between Phases (mm) 750 mm b Between Live Parts & Earth (mm) 508 mm 4 Distance between centers of outer stacks of insulators

(mm) 600 mm

5 Power Frequency withstand test voltage for completely assembled switches

a Against Ground i Dry KV 35 KV ii Wet KV 35 KV b Across Open Contacts i Dry KV 45 KV ii Wet KV 45 KV 6 Impulse withstand Test voltage of completely assembled

isolator switch with 1.2 / 50 micro second impulse wave

a Against ground KV (Peak) 75 KVP b Across the open ends of the phase KV (Peak) 85 KVP c Between Phases KV (Peak) 85 KVP 7 Particulars of the Contact a Type i Fixed Contacts Pressure relieving reverse loop type

contact ii Moving Contacts Tubular type moving contact b Material Electrolytic Cu. Strip for fixed contact

& Cu. Tube for moving contact c Size i Fixed Contact 25x5 copper strip-2 No. ii Moving Contacts OD 38xID32 mm copper tube d Current Density (Amps / mm2) i Fixed Contacts 2 A ii Moving Contacts 2.0 A iii Current take off assembly 2.0 A iv Aluminum Pad 1.0 A e Surface treatment and thickness of surface coating Contact area silver

plated, thickness 15




micron. f Contact Area 500 Sqmm g Contact Pressure Adequate h Contact support of fixed Contact MS Flat (HDG) 8 Current density at the minimum cross section of switch

blade (Amp / Sq.mm.) 2 Amp/Sqmm

9 Continuous Current Rating (Amp.) 630 Amps 10 Short Time Current Rating KA (rms) a For 1 sec. (KA rms) - b For 3 sec. (KA rms) 25 KA for 3 Second 11 Rated peak short Circuit Current KA (peak) 62 KA Peak 12 Momentary Current KA (rms) 25 KA 13 Temperature Rise Corresponding to a Maximum continuous rated current rated at 50ºC ambient Within limit of IS b Short time Current Rating i For 1 Sec. (ºC) As per IS ii For 3 Sec. (ºC) As per IS 14 Maximum Transformer magnetizing breaking current

which can be safely interrupted by the switch 0.7 Amps at 0.15 PF

15 Maximum current that can be safely interrupted between equipment bus bars

800 Amps

16 Maximum capacity current which can be safely interrupted by the isolator

800 Amps

17 Number of times isolator can be operated without any need for inspection

1000 Nos.

18 No. of operation which the switch can withstand without deterioration of contacts

1000 Nos.

19 No. of Break per Phase Two break per phase

20 Terminal Connectors a Clamp Body alloy composition Aluminum alloy b Bolts & Nuts size, material & tensile strength MS Electroplated

standard

c Type of Washers used Spring washer & plain washer

d Temperature rise when carrying rated current at 50ºC ambient (deg. C)

As per IS

e Weight of each type of Clamp (Kg.) To be indicated f Design of Clamp Suitable for Dog –

AAA conductor

21 Nuts and Bolts a Size, material and grade in current carrying path 3/8, ¼” size MS

Electroplated

b Size, material & grade in other parts 3/8, ¼” size M-12, MS Electroplated

22 Material and size of plate provided below & on top of insulators

MS Plate 8 mm thick on top of Insulator and 75x40 channel provided below insulator

23 Bearings a Material & Size of Bearing To be indicated b No. of bearings (location & size) 2 Nos. Bearing at

center post rotating

c Type of bearing Ball Bearing d Shaft dia of bearing To be indicated by

Bidder/manufacturer

e Distance between two bearing To be indicated by Bidder/manufacturer

24 Tandem Pipe a Size, Class & No. of Pipe 1” GI Pipe, B-class

1 No. For




isolator b No. of Bearing / Bush As per IS 25 Down pipe size and class <1” GI pipe B-Class 26 Type of Universal joints (a) Between bearing and down pipe Swivel Joint

( Universal Joint)

(b) Between down pipe and operating mechanism To be indicated 27 Safety factor taken into account while designing the

isolator 1

28 Weight of one three pole isolating switch (Kg) To be indicated 29 Torque required to open the switch 20 KGm(Approx) 30 Particulars of post insulator a) Make JSI/AC/Jaipur Class b) Type Post type insulator c) Tensile Strength 10 KN d) Weight 5 Kg. e) Nos. of units per stack 2 Nos. f) Diameter of stack in mm 160 mm g) Height of stack in mm 254 mm h) Creep age distance in mm (min. 320 mm) 320 mm i) Nominal system voltage 11 KV j) Highest system voltage 12 KV k) Visible discharge voltage 9 KV l) One minute dry withstand voltage KV (rms) 35 KV rms m) Power frequency flash over voltage KV 80 KV rms n) Impulse flash over voltage KV (peak) 105 KV o) Impulse withstand voltage KV (peak) 75 KV p) Puncture voltage KV 1. 3 times the actual

dry flash over voltage of the unit



10.0 POST INSULATOR 10.1 SCOPE

The specification covers Porcelain Post Insulator shells with metallic cap and base. These shells will be used for manufacturing of 11 KV 3-phase AB Switches or in other equipment in the system.

10.2 STANDARDS

Post Insulator should conform to latest applicable Indian / IEC standards and in particular to the IS:2544 specification for Porcelain Post Insulators. Polygon or compact solids core or long rod insulator is also acceptable. Creep age distance should be adequate for highly polluted outdoor atmosphere in open execution. The porcelain used for manufacture of post insulator shall be homogeneous free from flaws or imperfections that might affect the mechanical or dielectric quality. They shall be thoroughly vitrified through and impervious to moisture. The glazing of the porcelain shall be of uniform brown color, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base of the insulator shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing shall be avoided.

10.3 TEMPERATURE RISE

The maximum temperature attained by any part of the insulator when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree centigrade above ambient temperature. The corrections proposed shall be stated in the Bid and shall be subject to approval of the Employer.

10.4 INSULATOR CHARACTERISTICS

The insulator shall have the electrical and mechanical characteristics, which are given below:-

Highest system voltage 12 KV (rms) Dry one minute power frequency withstand voltage 35 KV (rms) Wet one minute power frequency with stand voltage

35 KV (rms)

Power frequency puncture with stand voltage 1.3 times the actual dry flash over voltage of the unit

Impulse voltage withstand voltage 75 KV (peak) Visible discharge voltage 9 KV (rms)

In this standard power frequency voltages are expressed as peak values divided by ½ and impulse voltage is expressed as peak values. The withstand and flashover voltage are referred to the reference climatic conditions.

10.5 MECHANICAL CHARACERISTICS The insulators shall be suitable for the minimum failing load of 10 KN. Nature of load will be transverse.

10.6 CREEPAGE DISTANCE

The minimum creep age distance of 11 KV Post Insulators shall be 320 mm for highest system voltage of 12 KV.

10.7 PACKING



All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport.

10.8 TEST The insulator shall comply with following tests as per IS:2544 -1973. 10.9 TYPE TESTS

Type tests are normally carried-out once and unless otherwise agreed to, test certificates giving the results of type tests, made on not less than 2 post insulators and post insulators unit identical in all essential details with those to be supplied are regarded as evidence of compliance. The tests should be carried out on two samples in the order mentioned below: -

(A) TEST ON BOTH INSULATORS

1. Visual examination 2. Verification of dimensions 3. Visible discharge test 4. Impulse voltage withstand test 5. Wet power frequency voltage withstand test 6. Dry power frequency voltage withstand test 7. Temperature cyclic test

(B) TEST ON FIRST INSULATORS

1. Mechanical strength test 2. Porosity test 3. Puncture test 4. Galvanizing test

10.10 ROUTINE TESTS The following shall be carried out as routine tests: -

1. Visual examination 2. Electrical routine test

10.11 ACCEPTANCE TEST

The test samples after having withstand the routine test shall be subject to the following acceptance tests in the order indicated below: -

1. Verification of dimensions 2. Temperature cyclic test 3. Mechanical strength test 4. Puncture test 5. Porosity test 6. Galvanizing test

Tolerance in insulator dimensions shall be as per the relevant Indian Standards. The Bidder/manufacturer shall invariably enclose with offer the type test certificates and guaranteed technical particulars.

10.12 MARKING Each insulator shall be legibly and indelibly marked to show the following: -

1. Name and trade mark of the manufacturer 2. Month and year of manufacturing 3. Minimum failing load in KN 4. Country of manufacturing

The above marking on porcelain shall be engraved and shall be applied before firing. Post insulator, without above markings shall not be accepted under any circumstances.



10.13 DESIGN, MATERIALS AND WORKMANSHIP

The Bidder shall assume full responsibility for co-ordination and adequate design. All materials used in the manufacturing of Insulator shall be of the appropriate class well finished and of approved design and make. All similar parts should be accurately finished and interchangeable. All ferrous parts including Bolts & Nuts etc. used on the post insulators shall be heavily hot dip galvanized. Specific attention shall be paid to tropical treatment to the entire insulator, as it will be subject to ring service, to extremely service exposure, to atmospheric moisture and to long period of high ambient temperature.

**********



11.0 HARD DRAWN STRANDED ALL ALUMINUM ALLOY CONDUCTOR FOR OVERHEAD POWER LINES

11.1 SCOPE:

This specification provides for the manufacture, testing before dispatch, supply and delivery of ISI marked All Aluminum Alloy (AAA) conductor.

11.2 STANDARD:

The conductor shall strictly comply with the Indian Standard Specification IS:398 (Part-IV)-1994 with the latest amendments unless otherwise stipulated in this specification, or any other International Standards which ensure equal or better quality material and workmanship.

11.3 MATERIAL: 11.3.1 The conductors shall be of best quality and workmanship. 11.3.2 The wires shall be smooth and free from all imperfections such as spills and splits and rolling

and wire drawing defects etc. resulting in reduction in cross-sectional area over the entire length.

11.4 TOLERANCE: The following tolerance shall be permitted:

i) Tolerance on Nominal diameter wires - plus/minus 1%. 11.5 MODULUS OF ELASTICITY AND CO-EFFICIENT OF LINEAR EXPANSION

The values of the final modulus of elasticity and co-efficient of linear expansion of AAA Conductor shall be as given hereunder:

Item No. of Wires Final modulus of

Elasticity GN/mm2 (Practical)

Co-efficient linear expansion per O° C

Density at temp. of 20°C

AAAC 7 0.6324×106 kg/cm2

23.0x10-6 Aluminum Alloy

2.7 kg/cm3 (Al. Alloy)

The wires of Aluminum Alloy Conductor shall be of heat treated aluminum, magnesium, silicon alloy having composition appropriate to the technical and electrical properties as specified in Table-I of IS:398 (Pt-IV)-1994.

11.6 JOINTS IN WIRES:

In AAA Conductors there shall be no joint in any wire/stranded conductor containing wires except those made in the base rod or wire before final drawing.

11.7 STRANDING 11.7.1 The wires used in the manufacture of a stranded conductor before stranding satisfy all

requirement of IS:398 (Part-II & IV)-1976 & 1994 with its latest amendments. The lay ratio of the layer shall be within the limit given below under clause 10.8.

11.7.2 In all construction, the successive layers shall have opposite directions of lay. The outer most

layer being right handed. The wires in each layer shall be evenly and closely stranded. 11.7.3 LAY RATIO: The lay ratio (ratio of the axial length of a complete turn of the helix formed by an

individual wire in a stranded conductor to the external diameter of the helix) shall be within the limit given below.

No. of Wires Lay ratio for Aluminum Alloy wire



11.8 PACKING AND MARKING: The conductor shall be wound in non-returnable reels or drums

conforming to IS: 1778-1961 (Specifications for reels and drums for bare wire) or the latest version thereof. The drums shall be marked with the following details:-

a) Manufacturer’s Name b) Trade mark, if any c) Drum No. & Identification Number d) Size of Conductor e) Number & lengths of pieces of Conductor on each Drum f) Gross Mass of the Packing g) Net Mass of Conductor h) ISI or relevant International Standard specification mark, if any i) Name and address of the Consignees

11.9 PACKING CONDITION 11.10.1 The reels/drums shall be of such constructions as to assure delivery of conductors free from

displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that the conductor surface is not dented, scratched or damaged in any way during manufacture, transport and erection. The conductor shall be properly lagged on the Drums.

11.10.2 The conductor drum should be suitable for wheel mounting. Before reeling, cardboard or other

suitable material shall be secured to the drum and inside flanges of the drums. After reeling the conductor, the exposed surface should be wrapped with suitable soft material e.g. polythene sheet etc. across the flanges to protect the conductor from dirt, grit and damage during transportation and handling and also prevent ingress of rain water during storage/transport.

11.10.3 All wooden components shall be manufactured out of seasoned wood of good quality free from

defect that may materially weaken the component parts of the Drums. Preservative treatment for anti-termite/anti-fungus shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor.

11.11 STANDARD LENGTH AND GROSS WEIGHT OF CONDUCTOR: The gross weight of each

package shall not exceed 1000 Kg subject to a tolerance of + 10%.

The standard wire length for AAA conductor shall be 2 Kms. Longer lengths shall be acceptable. Short lengths of not less than 50% of the standard lengths, as indicated above, shall be acceptable to the maximum extent of 10% of the total quantity.

11.12 TESTS 11.12.1 Samples of individual aluminum alloy wires for tests shall be taken before stranding from not

less than 10% of the spools/coils. If samples are taken after stranding they shall be obtained by cutting 1.2 meters from the outer end of the finished conductor from not more than 10% of the reels.

11.12.2 The mechanical tests shall be carried out on single wires only and not on complete conductor. 11.12.3 The following type tests and acceptance test shall be carried out on Aluminum Alloy Wires as

per detailed procedure given in IS:398 (Part-IV)-1994:-

a) Breaking Load Test b) Elongation Test c) Resistance Test

d) Wrapping Test 11.12.4 The rejection and re-test procedure shall be followed as stipulated in IS:398 (Part-II)-1976 and

IS:398 (Part-IV)-1994.

Outer Aluminum Alloy

Central Aluminum Alloy

Total Max. Min.

AAA Conductor

6 1 7 14 10



11.13 CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS The contractor/manufacturer of conductor shall arrange for the inspection by the representative of the Employer authorized for this purpose. At least 5% of the total number of drums of conductors taken at random shall be checked to ascertain the lengths of conductor adopting either of the following two methods:- a) The drum along with the conductor should be weighed and six empty drums along with

protective laggings & studs etc. normally used for winding the conductor should also be weighed. Net weight of the conductor should be calculated by subtracting the average weight of the six empty drums from the gross weight of the conductor and drums. Having known the weight of the conductor, the length of the conductor can be computed.

In case of empty conductor drums, a check weighment of every one in ten empty drums shall also be done before the conductors are wound on the drums.

b) Arrangements should be made available in the works of the manufacturer for transferring the

conductor from one reel to another at the same time measuring the length of the conductor so transferred by means of Length measurement machines. Percentage shortage if any in the length thus obtained and as declared by the Bidder/manufacturer/Manufacture in the packing list shall be applied to all the drums.

11.14 CHECK MEASUREMENT 11.14.1 Where length of conductor is verified by weighment basis the determining factor will be

length/weight ratio of the sample drums verified at the Bidder/manufacturer’s/Manufacturer’s premises of the lot of which the drum under measurement at the consignee’s end forms a part.

11.14.2 In case, where the recorded weight on the drum tallies with the measured weight at consignee

end, then the conductor length shall be accepted as recorded on the drum. In other cases, the determining factor will be weight/length ratio of the sample(s) inspected at the manufacturer’s premises of the lot of which the drum under measurement at the consignee’s end, forms a part. The factors of weight/length ratio shall however be made available to the Employer in the dispatch instructions itself. If such factors are not available due to some reasons, actual measurement of diameter shall be made and weight/length ratio shall be obtained for the purpose of computing length.

11.15 SIZE AND PROPERTIES OF AAA CONDUCTORS i) For AAA Conductors (As per IS:398 (Pt-IV)-1994)

Conductor (Code word)

Actual Area

Stranding & Wire Dia

Approximate overall Dia

Approximate Mass

Calculated Maximum resistance at 20°C

Approximate Calculated breaking load

mm2 mm mm Kg/km Ohm/km KN Rabbit 55 7/3.15 9.45 149.20 0.6210 16.03 Dog 100 M 7/4.26 12.78 272.86 0.3390 29.26

ii) PROPERTIES OF ALUMINUM ALLOY WIRES USED IN THE CONSTRUCTION OF AAA

CONDUCTORS Size (Code-word)

Diameter Gross Sectional Area of Nominal Dia. wire

Mass Resistance 20°C

Breaking Load (Min.)

Nominal Min. Max. Before Stranding

After Stranding

1 2 3 4 5 6 7 8 9

mm2 (mm) (mm) (mm) (mm2) (Kg/Km) Ohm/Km KN KN

Dog 4.26 4.22 4.30 14.25 38.48 2.345 4.18



55 (Rabbit)

3.15 3.12 3.18 7.793 21.04 4.290 2.41 2.29

GUARANTEED TECHNICAL PARTICULARS OF ALL ALUMINUM ALLOY CONDUCTOR

Sr No

Parameters Unit

To be categorically specified by the tenderer AAAC RABBIT

AAAC Dog.

1

Particulars of Raw-material Aluminum Rods Complete Conductor

1.1

Aluminum a) Min. purity of Aluminum b) Max. Copper Content

% %

1.2 Zinc N.A. 2.0 Aluminum Strands after stranding 2.1

Diameter Nominal Maximum Minimum

Mm Mm Mm

2.2 Min. Breaking load of strand KN 2.3 Max. Resistance of 1 m length at 20ºC Ohm/ Km 3.0

Lay ratio of Conductor 1/6 Layer

Min / Max

4

Modulus of elasticity and coefficient of linear expansion a) Final Modules of elasticity b) Coefficient of linear expansion

GN/m2

/ºC

5 DC Resistance of Conductor at 20 deg C Ohm/ Km

6

Standard length of conductor Mtr

7

Tolerance on standard length

Mtr.

8

Direction of lay for outside layer

9

Linear mass of the Conductor a) Standard b) Minimum c) Maximum

Kg/Km Kg/Km Kg/Km

10 No. Of Cold Pressure butt welding available at works

No.

12.0 HELICALLY FORMED FITTINGS: 12.1 Pin Insulator ties:

Helically formed insulator ties shall be suitable for specified conductor size. Helically formed ties used for holding the conductor on the pin insulator shall be made of aluminum alloy or aluminized steel or aluminum-clad steel wire and shall conform to the requirement of IS:12048-1987. The ties shall be suitably for pin insulator dimensions and conductor sizes to be specified by the Employer. Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into direct contact with the insulator. Tests: The ties shall be subjected to the tests specified in IS:12048-1987.



12.2 Fittings for Strain Insulators: The Fittings shall consist of the following components:

• Cross arm strap conforming to IS:2486 (Part-II) – 1989. • Aluminum alloy die cast thimble – clevis for attaching to the tongue of Strain insulator at one

end and for accommodating the loop of the helically formed dead-end fitting at the other end in its smooth internal contour. The thimble shall be suitable for all sizes of conductors ranging from 7/2.11mm to 7/3.35mm AAAC. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a non-ferrous split pin of brass or stainless steel. The thimble shall have clevis dimensions as per IS:2486 (Part – II)-1989.

• Helically formed dead-end grip having a prefabricated loop to fit into the grooved contour of the

thimble on one end for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS:12048-1987.

Tests: The helically formed fittings for Strain insulators shall be subjected to tests as per IS:12048-1987. The other hardware fittings shall be tested as per IS:2486 (Part-I).



12.0 TECHNICAL SPECIFICATION FOR 11 KV V.C.B.

SCOPE :- This specification covers design, manufacturing, testing, of 11 KV Porcelain Clad Vacuum Circuit Breakers complete with all accessories required for its satisfactory operation for the Transmission/Sub T transmission solidly grounded system. The Breaker shall be used for Feeder Control/ protection in the system.

TYPE AND RATING :- The circuit breaker shall be suitable for outdoor operation under the climatic conditions as specified in Tender Specification without any protection from sun and rain. The 11 KV circuit breakers shall have the following rating:-

The above is minimum requirement. The suppliers may offer their standard design keeping in view our

minimum requirements.

The circuit breakers shall comply with the requirements of IS:13118(1991) or IEC 62271-100 with latest amendment thereof.

12.1 VACUUM INTERRUPTER(VI) 12.1.1 The design of the vacuum interrupter shall be such that it gives trouble free operation under

normal load and fault conditions throughout the life of the equipment. As the efficiency of the breaker depends on the degree of vacuum inside, it has to be ensured by the that manufacturer that the it is maintained consistently during service. To know the residual life of vacuum interrupter, an indicator/means to indicate status of contact erosion should be provided.

12.1.2 Insulating ceramic body of the interrupter should have high mechanical strength and it should

be capable of withstanding high temperature without any significant deterioration in its mechanical and electrical properties.

12.1.3 The metal/alloy used for the fixed and moving contacts shall have very low resistivity and low

gas content. They should be resistant to arc erosion and the contact should have no tendency to get cold welded under the high vacuum in the interrupter.

12.1.4 The interrupter design should ensure rapid de-ionization of the gap so that normal electrical

strength of the gap is restored instantaneously.

12.1.5 The metallic bellow or any other similar vacuum sealing arrangement should be provided at the moving contact and should have a long fatigue life.

s.n. Particulars 11 KV

i. Number of Poles 3

ii. Frequency 50 cycles

iii. Nominal system voltage 11 KV

iv. Highest system voltage 12 KV

v. Interrupting capacity at nominal system

voltage

500 MVA

vi. Rated continuous current 630 Amps

vii. Short-time current rating 25 KA for 1 sec. .

viii L.I voltage withstand for one Minute 75 KVp

ix. Power frequency withstand voltage for

one Minute

28 KV

x. Total break-time for any current up to the

rated breaking current

5 cycles (max.)

xi. Control circuit voltage 30 Volt D.C.

xii. Operating duty for gang operation O-0.3sec.-CO-3 min-CO

Minimum clearances

a. Phase to Phase 280 mm (-10 mm+…)

b. Phase to earth 190 mm

c. Creepage distance (min.) 300 mm

d. Between live parts & ground 2750 mm



34.9.6 Manufacturer’s catalogue of vacuum bottle, indicating all the details shall essentially be

submitted. 12.2 MOUNTING OF CTs

The offered steel structures for breakers should also have adequate strength to accommodate 3 nos. CTs on it with provision of suitable supports from ground.


The maximum temperature attained by any part of the equipment, when in service at site, under continuous full load conditions, exposed to the direct rays of the sun, shall not exceed 45˚ C above ambient temperature. The limits of temperature rise shall be as per relevant standard.

12.4 INSULATION OF THE CIRCUIT BREAKER

The insulation to ground, the insulation between open contacts and the insulation between phases of the completely assembled circuit breaker shall be capable of withstanding satisfactorily di-electric test voltage corresponding to specified basic insulation level in the standard.

12.5 INSULATORS Basic insulation level of the insulator and insulating porcelains shall be as specified and porcelain shall be homogenous and free from cavities and other flaws. They shall be designed to have ample insulation, mechanical strength and rigidity for satisfactory operation under conditions specified above. All insulators of identical ratings shall be inter-changeable. The puncture strength of the insulators shall be greater than the flash over value.

12.6 OPERATING MECHANISM 12.6.1 The circuit breaker shall be designed for remote control from the control room and in addition

there shall be provision for manual operation of circuit breakers during maintenance and for local tripping and closing by normal means.

12.6.2 The circuit breakers shall have operation counter and mechanical “open” and “closed”

indicator, in addition to facilities for remote electrical indication. An operation counter shall also be provided in the common operating mechanism. The mechanical indicator and operation counter shall be located in a position where it shall be visible to a man standing on the ground level with the mechanism housing doors are in closed position.

12.6.3 The operating mechanism shall be of the spring charging type, by electric control under normal

operation. The mechanism shall be trip free electrically and mechanically. Mechanism shall also be capable of performing satisfactorily, the re-closing duty cycles. All working parts in the mechanism shall be of corrosion resistant materials and all bearings which require greasing shall be equipped with pressured grease fittings. The mechanism shall be strong, quick in action and removable without disturbing other parts of the circuit breaker. Mechanism and breaker shall be such that the failure of any spring will not prevent tripping and will not cause tripping or closing. Operating mechanism should be motor operated spring charged type preferably without chain drive. Motor for spring charging shall be suitable to perform satisfactorily for input supply voltage of 230V AC 50 Hz with a variation of plus 10 and minus 20 percent. A.C. motor should have overload protection. Provision should also be made for mounting of mechanism box at an adequate height and gear ratios shall be so chosen that one man should be able to charge the spring, without any additional efforts. The mechanical arrangement should be provided to facilitate manual tripping of circuit breaker for emergency trip under emergent condition i.e. failure of DC supply, trip coil burnt, mechanism being defective while arc quenching media is healthy.

12.7 MOTORS:

(i) Motors shall be single phase self-starting induction motor of appropriate capacity for satisfactory operation for the application and duty as required for driving equipment. (ii) Motors shall be of self ventilated type having TEFC (totally enclosed fan cooled) enclosure.



(iii) Depending upon the capacity and loading conditions Bidder/manufacturer shall design suitable grease lubricated or oil lubricated bearings for above motors. Bearing shall be so constructed that the loss of grease and its creeping along with shaft into motor housing is prevented. It shall also prevent dirt and water from getting into the motor.

(iv) Continuous motor rating (name plate rating) shall be at least ten (10) percent above the maximum load demand of the driven equipment at design duty point and the motor shall not be overloaded at any operating point of driven equipment that will arise in service.

(v) Motors shall be capable of giving rated output without reduction in expected life span when operated continuously in the system having the particulars as given in principle parameters.

(vi) All induction motors shall be suitable for full voltage direct-on-line starting. These shall be capable of starting and accelerating to the rated speed along with the driven equipment without exceeding acceptable winding temperature even when supply voltage drops down to 80% of the rated voltage.

12.8 CONTROL CUBICLE A common control cubicle shall be provided to house electrical controls, monitoring devices and all other accessories, except those which must be located on individual poles. Cubicle shall be IP-55 of gasketed weather-proof construction, fabricated from sheet steel of minimum 2.5 mm. thickness. The cubicle shall have front access door with lock and keys. Space heater, internal illumination lamp, 3-pin 5A socket with individual ON-OFF switches. For local operation following shall be provided: -

a) LOCAL/REMOTE selector switch b) TRIP/NORMAL/CLOSE control switches with pistol grip handle.

12.9 The control circuits shall be designed to operate on 30V DC and it shall be possible to adopt

to work on other voltages by simply changing the operating coils. Shunt tripping coils shall be designed to operate satisfactorily within 70% to 110% and shunt closing coil within 85% to 110% of the rated DC voltage.

12.10 AC Power supply for auxiliaries will be available at 230V single phase 50 Hz.

12.11 Necessary cable glands for the cables of the operating mechanism shall be provided. The

cables used for operation are un-armoured 2.5 sq. mm. copper control cables of 1100 V grade. Cable glands provided may therefore be suitable for 1 no. 8 core and 2 nos. 4 core un-armoured 2.5 sq. mm. copper control cable.

12.12 Circuit breaker shall be provided with trip free mechanism so that tripping instructions could

over-ride the closing instructions. An additional tripping coil shall also be provided in the trip circuit. The second coil shall have separate tripping lever arrangements in the mechanism, so as to avail full advantage of second trip coil. Also the two trip coils shall have separate DC circuits, so that in the event of any short circuit/ damage in any one of the trip coil, supply is available in the other one.

12.13 Circuit diagram of control circuit of VCB along with operating instructions (DO’S/ DON’T) shall

be embossed on metallic plate duly laminated and the same shall be fixed on the rear door of the control cubicle from inside.

12.14 WIRING

(i) Wiring shall be completed in all respects to ensure proper functioning of the control,

protection, monitoring and interlocking schemes. (ii) All wiring shall be carried out with 1100V grade PVC insulated stranded copper conductor

of 2.5 sq. mm.

(iii) Each wire shall be identified at both ends with permanent markers bearing wire numbers as per wiring diagram.

(iv) Wire termination shall be done with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals.

(v) All spare contacts of auxiliary switches etc. shall be wired up to terminal blocks in the control cubicle.



12.15 TERMINAL BLOCKS (i) Terminal blocks shall be of 1100V grade, box clamp type ELMEX 10 sq.mm or approved

equivalent. Not more than two wires shall be connected to any terminals. Spare terminals, equal in number to 20% of active terminals, shall be provided.

(ii) Terminal block shall be such located that it allows easy access. Wiring shall be so

arranged that individual wires of an external cable can be connected to consecutive terminals.

12.16 TERMINAL CONNECTORS

(i) All circuit breakers shall be provided with 6 nos. terminal connectors suitable to receive Dog ACSR/AAA conductors. Clamps shall be designed adequately to take care of any bimetallic effect. Terminal connectors shall be tested for short circuit current capability, temperature rise.

ii) Terminal connector shall also meet the following requirements: a) Terminal connectors shall be manufactured & tested as per IS:5561. b) All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp

edges and corners shall be blurred and rounded off. c) No part shall be less than 12 mm thick. d) Nuts, bolts & washers used in the current path shall be stainless steel. e) Bimetallic strips/sleeve copper alloy liner of minimum thickness of 2mm shall be cast

integral with Aluminum body. f) All current carrying parts shall be designed and manufactured to have minimum contact

resistance. g) Terminal connectors should be made of A6 Aluminum Alloy and manufactured by gravity

die-casting process only. Sand die-casted connectors are not acceptable. h) Size of terminal connector for which the clamp is designed and also rated current under site

conditions shall be embossed/ punched on each part of clamps, except hardware. i) Conductor shall be tightened by at least four bolts. Conductor hold length must not be less

than 60 mm. j) Surface of clamps to be tightened by bolts should be flat in shape, so that it may be

possible to open the nuts and bolts by normal spanners. Therefore, any type of groove in the clamp body for fixing of nuts should be avoided.

k) Portion of clamp to hold the conductor should be flat and straight and not zigzag in construction at both the sides, so that heating of clamp by throttling action of current may be avoided.

l) Space of at least 50% of diameter of nuts should be available after hole at both the sides of conductor holding portion for better mechanical strength.

12.17 AUXILIARY CONTACTS

Eight numbers each of auxiliary contacts both of the normally open and normally closed types shall be provided in each circuit breaker for use in remote indication and control scheme of the circuit breaker and for providing safety interlocking. Special contacts for use with trip coils which permit for relative adjustment with respect to the travel of the circuit breaker shall also be provided. Wherever required, there shall be provision to add more auxiliary contacts at a later date, if required. All auxiliary contacts shall be placed in a weather proof casing and current rating of the contacts shall be as mentioned in the bid. Provision shall be available to convert these spare “normally-open” contacts to “normally-closed” type and vice versa.

12.18 ACCESSORIES

Circuit breaker shall be supplied as a complete unit with internal wiring installed and terminated in mechanism box and equipped with the following accessories :-

(i) Motor operated spring charged mechanism : 1 No. (Motor voltage - 230 V AC, 50 Hz) (ii) Trip coil suitable for 30 V DC : 2 Nos. (iii) Closing coil suitable for 30 V DC : 1 No. (iv) Pistol grip C.B. Control switch having : 1 No. Trip /normal /close position (v) Local/remote selector switch : 1 No. (vi) Spring Charged indicator : 1 No. (vii) Manual operating handle for maintenance : 1 No. (viii) Facility for manual charging of spring : 1 No. (ix) Operation counter : 1 No.



(x) Auxiliary contacts (8 NO - 8 NC) : 1 Set (xi) Anti pumping device suitable for 30 V DC : 1 No. (xii) Bimetallic terminal connectors suitable for : 6 Nos.

connecting Dog ACSR/AAA conductor. (xiii) Cubicle illuminating lamp with protective : 1 No. cage and on/off switch (xiv) Spare terminals block : 20% of the Total active terminals (xv) Mechanical ON/OFF Indicator : 1 No. (xvi) MCB for both AC and DC supply : 1+1 No. (xvii) Space heater with thermostat and : 1 No.

ON/ OFF switch (xviii) 3-Pin 5 A socket with on/off switch : 1 Set (xiv) Earthing terminals : 2 Nos. (xx) Foundation Bolts : As per requirement (xxi) Cable glands : As per requirement

Other accessories which are not specified above, but are required for efficient and trouble free operation of breaker, should also be provided without any extra cost.

12.19 TYPE TESTS

(i) Type test certificates for the following tests, as per IS:13118 or IEC 62271-100 with latest amendment thereof, from any of the NABL accredited Laboratory shall invariably be furnished

a. Short circuit duties test b. Short time withstand current and peak withstand current tests c. Temperature rise test d. Mechanical endurance test e. Lightning impulse voltage withstand test f. Power Frequency withstand voltage test (dry & wet) g. Single Capacitor bank switching test h. Degree of protection IP-55 as per IS:13947:93(Part-I)/IEC 60529:89

(ii) Type test certificates must accompany drawing of type tested equipment, duly sealed & signed by type testing authority.

(iii)Type tests should not have been conducted on the equipment earlier than 3 years from the date of opening of bids.

(iv) In case of any change in design/type of breaker already type tested and the one being offered against this specification, the Employer reserves the right to demand repetition of some or all tests without any extra-cost at NABL accredited lab.

12.20 ACCEPTANCE AND ROUTINE TEST :- 12.20.1 Employer shall have access at all times to the works and all other places of manufacture where

the Circuit Breakers are being manufactured and the Bidder shall provide all facilities for unrestricted inspection of the Bidder/manufacturer’s works, raw materials, manufacture of all the accessories and for conducting necessary tests as detailed herein. The Employer reserves the right to insist for witnessing acceptance/routine testing of the bought out items. The Bidder/manufacturer shall submit the routine test certificates of bought out items and raw material also, at the time of routine testing of the fully assembled breaker

12.20.2 No material shall be dispatched from its point of manufacture unless the material has been

satisfactorily inspected and tested. 12.20.3 Bidders shall indicate the inspections and checks carried out at various stages of manufacture

of the circuit breakers. Complete record of stage inspection would be kept by the Bidder/manufacturer and this record should be made available for inspection by the representative of the Employer. Bidder/manufacturer should indicate the manufacturing programme and the The Employer will have a right to depute inspecting officers during the manufacture of the equipment. The Employer reserves the right to carry out stage inspections at all stages, for which advance intimation shall be given and all necessary cooperation shall be rendered by the manufacturer.

12.20.4 At the time of inspection, Bidder/manufacturer shall identify each and every

item/accessories of the particular Circuit Breaker under testing. Unless all the items are identified, the manufacture will not be treated as complete. Various tests stipulated in



IS/IEC shall be performed in the presence of the Employer’s engineers or when the inspection waiver has been given, in such a case, testing shall be done at the manufacturer's works as per IS/IEC stipulations and same should be confirmed by documentary evidence by way of Test Certificate which shall be got approved by the Employer.

12.20.5 It is expected that before circuit breaker is finally offered for inspection, internal testing of the

same for various important parameters are already done. Routine test report for such tests shall also accompany the letter of inspection call so that the Inspecting Officer at the time of inspection may verify the parameters brought out in the preliminary report. Details of all tests should be clearly brought out.

12.20.6 In case for any reason, inspection is not completed or equipment is not found to be complete with all accessories as per confirmation given with the letter of inspection call, the Employer will reserve the right to recover complete cost of deputation of inspecting team to the works of the manufacturer.

12.20.7 Acceptance of any quantity of circuit breaker & its accessories shall in no way relieve the

successful bidder of his responsibility for meeting all the requirement of this specification and shall not prevent subsequent rejection if such equipments are later found to be defective.

12.21 RATING PLATES & SURFACE FINISH PAINTING & GALVANISING:- 12.21.1 Each circuit breaker shall be provided with a detailed rating plate. Details on the rating plate

shall be as per ISS and shall also indicate manufacturer name, serial no., order no. and month & year of dispatch.

12.21.2 All interiors and exteriors of tanks, mechanism, enclosures, cabinets and other metal parts

shall be thoroughly cleaned to remove all rust, scales, corrosion, greases or other adhering foreign matter. All steel surfaces in contact with insulating oil, as far as accessible, shall be painted with not less than two coats of heat resistant, oil insoluble, insulating paint.

12.21.3 All metal surfaces exposed to atmosphere shall be given two primer coats of zinc chromate

and two coats of epoxy paint with epoxy base thinner or hot dip galvanized or two packs of aliphatic polyurethane finished paint. All metal parts not accessible for painting shall be made of corrosion resistant material. All machine finished or bright surfaces shall be coated with a suitable preventive compound and suitably wrapped or otherwise protected. Paints shall be carefully selected to withstand tropical heat and extremes of weather within the limits specified. Paint shall not scale off or wrinkle or be removed by abrasion due to normal handling. All external paintings shall be as per shade no. 697 of IS:5 or polyurethane paint having shade siemens graph RAL7032. All ferrous parts & steel structure including all sizes of nuts, bolts, plain and spring washers, support channels, structures, etc. shall be hot dip galvanized or stainless steel or electro-galvanized.

12.22 DOCUMENTATION: 12.23 List of Drawings and Documents: 12.23.1 Bidders shall furnish four sets of relevant descriptive and illustrative published

literature, pamphlets and following drawings for preliminary study;

(a) General outline drawings showing dimensions and shipping weights. (b) Sectional views showing the general constructional features of the circuit breaker

including operating mechanism, arcing chambers, contacts with lifting dimensions for maintenance.

(c) All drawings & data typical and recommended schematic diagram for control supervision & reclosing shall be annotated in English. .

(d) Schematic diagrams of breaker offered for control supervision and reclosing. (e) Structural drawing, design calculations and loading data for support structures. (f) Short circuit oscillogram & certificates for similar type tested breakers. General

arrangement of foundation and structure mounting plan including weights of varnish components and impact loading data for foundation design.

(g) Type test reports.

12.23.2 Successful bidders shall, within two weeks of placement of order, submit four sets of final version of all the above drawings for the Employer's approval. The Employer shall communicate his comments/approval on the drawings to the Bidder/manufacturer within two



weeks. Bidder/manufacturer shall, if necessary, modify the drawings and resubmit four copies of the modified drawings for the Employer's approval within two weeks from the date of comments. After receipt of the Employer's approval, the Bidder/manufacturer shall, within three weeks, submit 4 prints per breaker and two set of good qualities reproducible of the approved drawings for the Employer's use.

12.23.3 Successful bidders shall also furnish two sets each of bound manuals covering erection,

commissioning, operation and maintenance instructions and all relevant information and drawings pertaining to the main equipment as well as auxiliary devices alongwith each breaker. Marked erection drawings shall identify the component parts of the equipment as shipped to enable erection by the Employer’s own personnel. Each manual shall also contain one set of all the approved drawings, type test reports as well as acceptance reports of the corresponding consignment dispatched.

12.23.4 Manufacturing of equipments shall be strictly in accordance with the approved drawings and

no deviation shall be permitted without the written approval of the Employer. 12.23.5 Approval of drawings/work by the Employer shall not relieve the bidders of any of his

responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of the applicable standards rules and codes of practices. Equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of supply and the Employer reserves the right to reject any equipment or material which, in his judgment, is not in full accordance therewith.

12.23.6 Additional data to be furnished along with the bid:

(a) Drawing, showing contacts in close, arc initiation, full arcing, arc extinction, and open position.

(b) Data on capabilities of circuit breakers in terms of time and number of operations at duties ranging from 100% fault currents to load currents of the lowest possible value without requiring any maintenance or checks.

(c) Effect of non-simultaneity between contacts within a pole or between poles and also how it is covered in the guaranteed total break time.

12.24 PACKING AND FORWARDING: Equipment shall be prepared for ocean shipment (foreign equipment) or rail road transport (local equipment). Equipment shall be packed in suitable crates in such a manner to protect it from damage and withstand handling during transit. Bidder/manufacturer shall be responsible for and make good at his own expense any or all damage to the equipment during transit, due to improper and inadequate packing and handling. Easily damageable materials shall be carefully packed and marked with the appropriate caution symbols. Wherever necessary, proper arrangement for lifting such as lifting hooks etc. shall be provided. Any material found short inside the packing cases shall be supplied by the Bidder/manufacturer without any extra cost. Each consignment shall be accompanied by a detailed packing list containing the following information:

(a) Name of the consignee.

(b) Details of consignment.

(c) Destination.

(d) Total weight of consignment.

(e) Sign showing upper/lower side of the crate.

(f) Handling and unpacking instructions.

(g) Bill of material indicating contents of

each package and spare material.

12.25 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS: Bidders must furnish following information along with technical bid.



12.26 A list of all the accessories which will be supplied with the breakers should be furnished. While furnishing the list of accessories, items which will be manufactured by the Bidders and balance items, which will be procured from sub-Bidder/manufacturers should be clearly identified and stipulated in the bid.

12.30 GUARANTEED TECHNICAL PARTICULARS: It is obligatory on the part of bidders to furnish Guaranteed Technical Particulars enclosed with

the bid document duly filled in complete in all respects. In case Guaranteed Technical Particulars duly filled in complete in all respects is not furnished, the bid may be treated as non-responsive

12.31 SCHEDULE OF REQUIREMENT OF ACCESSORIES ETC

It is obligatory on the part of bidders to furnish Schedule of Requirement of Accessories provided with equipment in the Schedule A attached.

12.32

GUARANTEED TECHNICAL PARTICULARS FOR 11 KV VCBs

NOTE: This schedule of guaranteed technical particulars is to be submitted by the Bidders. It may be carefully noted that filling/ reply of each and very clause described below is a must.

GUARANTEED TECHNICAL PARTICULARS FOR 11KV

Sr. No

Particulars 11 KV

1 Name of manufacturer & Place of manufacture 2 Manufacturer’s type Designation of VCB 3 Rated Nominal voltage (KV) 4 Rated Highest Voltage (KV) 5 Rated Normal Current (Amps) 6 Rated frequency (HZ) 7 Rated short circuit breaking current (KA) 8 Rated short circuit making current (KAp) 9 Rated PF withstand voltage (KV) 10 Rated LI withstand voltage (KVp) 11 Rated Short Time Current for 1 sec. (25KA) 12 Rated operating sequence 13 a) Rated Aux. supply for spring charging motor

b) Spring charging motor rating/make c) Spring charging motor time (ms) d) Detail of overload protection provided for spring

charging motor

14 Rated supply of tripping/ closing coils 15 Power required for tripping/ closing coils 16 No. of poles 17 No. of breaks/pole 18 Class (outdoor) 19 Applicable standards 20 Type of Operating mechanism 21 Vacuum Interrupter details

(a) Make (b) Model No./type, designation (c) Voltage/Current rating (d) STC rating & Duration (e) Type of contacts (f) Material of contacts (g) Contact pressure at no load (h) Electrical life

(i) At rated normal current (ii) At rated short circuit current

(i) Mechanical life



22 Maximum temp. rise over ambient temp. 23 Breaking capacity (KA)

a. Symmetrical b. Symmetrical at rated service voltage c. Asymmetrical

24 Total break time in milli second a. At 10% rated interrupting capacity b. At rated interrupting capacity

25 Arcing time in milli-sec a. At 10% breaking capacity b. At 100% breaking capacity

26 Minimum closing time from the instant of trip coil energisation (ms)

27 Rated transient recovery voltage 28 a) Data on re-striking voltage

i. Amplitude factor 100% & 50% of rated capacity ii. Natural frequency

iii. Phase factor iv. R.R.V. Volts/micro second

29 Minimum clearance in air (mm) i. Between phase & Earth ii. Between phases iii. Live parts to ground level

30 Make, Type of support insulators, creep age distance

31 Make, Type of insulator containing VI creep age distance

32 Total length of break per phase 33 Total break time (milli-sec) 34 Opening time (milli-sec) 35 Closing time (milli-sec) 36 Opening speed (Meter/Sec) 37 Closing speed (Meter/Sec) 38 DC component of rated short circuit breaking

current

39 First pole to clear factor 40 Number of auxiliary contact provided & type

i. Normally open ii. Normally closed iii. Those adjustable with respect to the position of

main contacts

41 Accessories to be supplied with each breaker 42 (a) Rated cable charging breaking current

(b) Rated back to back on capacitor bank breaking current

(c) Rated capacitor bank inrush making current

43 Rated single capacitor breaking current 44 Maximum over voltage on switching transformer on

No-load and the charging current

45 Total weight of one complete Breaker 46 Overall dimension of VCB (mm) including structure 47 Dimension, weight of mounting structure 48 Procedure followed to ensure achievement of

parameters Simultaneity of contact, Contact travel, Contact speed

49 Please indicate measures provided to trap moisture, if any, inside the hollow porcelain containing the vacuum interrupter

50 Measures provided to indicate for loss of vacuum 51 Measures provided to indicate for wear/ tear of

contacts



PANEL HAVING GEAR MECHANISM & CONTROL CIRCUIT

SCHEDULE A DETAILS OF FITTING & ACCESSORIES TO BE PROVIDED WITH 11KV VACUUM CIRCUIT BREAKERS

S. No. Particulars Qty. Rating Make

1 Sheet thickness of breaker panel 2 Size of control wiring 3 GI Mounting Structure (Breaker & CT) 4 Color code for control wiring 5 Type of Operating Mechanism 6 Rating of Diode protection (in case of D.C. Spring

charging motor)

7 Make & Rating of Heater & thermostat 8 Color shade of VCB control panel 9 Make & Rating of Anti-pumping relay 10 Make & Type Operation counter 11 Spring charged indicator 12 Mechanical ON/OFF Indicator 13 Facility for manual charging of breaker 14 Auxiliary contact 8 NO + 8NC 15 Cubical illumination lamp with protective cage & on/off

switch

16 Make & Rating of MCB for AC/DC circuits 17 Make & Rating of C.B. Control switch having

Trip/Normal/Close Position

18 Make & Rating of Local/Remote selector switch 19 3 Pin 5 Amps Socket with on/off switch 20 Nos. & Size of foundation Bolts 21 Material supplied in loose with each VCB 22 Provision of double trip coil 23 Provision of 2 nos., 4 core and 1 no. 8 core cable

glands suitable for 2.5 sq.mm. unarmored copper control cable

24 Provision of circuit diagram with operating instructions (DO’S & DON’T) embossed on metallic plate duly laminated to be fixed on inside wall of rear door of control cubicle.



13.0 SPECIFICATION FOR 11 KV INDOOR CONTROL PANELS

SCOPE

This section contains the technical specification for the multi circuit indoor control, indication, relay and metering panels for control of associated line or transformer through outdoor switchgear at various 33/11 KV Zonal sub-stations. The control and relay panels and other requirements specified under this section shall be complete in themselves with all main and auxiliary relays, annunciation relay, fuses, links, switches, wiring, labels, terminal blocks, earthing terminals, base frame, foundation bolts, illumination, cable glands etc. 13.1 PANEL FINISH AND COLOUR:- The purchaser has standardized that the colour finish shall be opaline green as per color no. 275 of BS: 381C (1948). Equivalent colors as per relevant Indian Standards or any other standard are also acceptable. This color finish shall be applied to all the exterior steel work of the panels. The exterior finish shall be semi glossy only and shall not be fully glossy. The interior of the panels shall be painted with egg shell white. 13.2 PROTECTIVE RELAYS AND INSTRUMENTS:- The protective relays shall be manufactured, tested and supplied with the guaranteed particulars, as per following Indian Standard Specifications with latest amendment thereof :- (i) IS-3842 (Part-I):1967 : Application guide for electric relays for A.C. Systems over- current

relays for Feeders and Transformers (ii) IS-3842 (Part-IV):1967 : Application guide for electric relays for A.C.system thermal

protection relays (iii) IS-3231 (1965) : Electric relay for power system protection (iv) IS-1885 (Part-I&II) : Electro-technical vocabulary Electrical relays & Electrical power

system protection (v) IS-4483 : Preferred panel cut-out (vi) IS-1248 : Indicating instruments (vii) All indicating instruments shall conform to IS-722 or BS-89 or any equivalent or better international

standards...

The equipment meeting any other authoritative standards which ensures equal or better quality than the standards mentioned above shall also be acceptable. Equipment for which Indian Standards are not available the relevant British Standards and IEC recommendations will be applicable. The bidder has to submit copies of all applicable standards along with the offer.

13.3 TYPE/ ACCEPTANCE TEST CERTIFICATES FOR RELAYS:- Following type test certificates of relays as per IS: 3231 or any equivalent international standard are required to be submitted by the bidder:-

(i) Performance test and operating characteristic tests (ii) Thermal requirement test (iii) Accuracy test (iv) Re-set value test (v) Re-set time test (vi) Over shoot time test (vii)Rated burden & impedance test (viii)Insulation requirement test (ix) Mechanical requirement test (x) Contact performance test

NOTE

Regarding testing of relays, reference may please be made to BS-142-19.

13.4 PANEL CUT OUT AND DIMENSIONS:- (i) The panels shall be fabricated from 2mm steel sheet free from all surface defects. The panels shall

have sufficient structural re-enforcement to ensure a plane surface to limit vibration and to provide rigidity during dispatch and installation. All control panels and switchgear cubicles shall be made absolutely vermin-proof. Pre-treatment & painting of panels shall be done as per the procedure detailed in clause-22 of this schedule.

(ii) The panels shall have the following dimensions :- Height 1475 mm Depth 300 mm Width 600 mm



No deviation in height and depth is permitted. However, to accommodate instruments, relays, control and indication gadgets of different make, increase in panel width alone is permitted, subject to specific approval of purchaser.

(iii)The preferred panel cut out dimensions for mounting of the relays shall be as per Indian Standard Specification IS-4483 (Part - I & II).

(iv) Design, material selection and workman-ship shall be such as to present a neat appearance, outside and inside with no works of welds, rivets, screw or bolts head apparent from the exterior surface of the Control Panels.

13.5 PANEL LIGHTING:- a) For interior illumination, 11/15 Watt CFL operating at 230V AC 50 Hz with On/Off switch shall be

provided in each panel. The lamp/tube shall be located at the ceiling and guarded with protective cage. The On/Off switch shall be mounted on one of the sidewalls and shall be easily accessible.

b) One 3 pin-5 Amp. receiptable socket with On/Off switch and fuse shall be provided in each control panel.

13.6 INDICATING LAMPS:-

The indicating lamps should be supplied with low voltage protection circuit (LVGP) and surge suppressor circuit having LED indication. Lamp assembly should be of fire retardant glass epoxy PCB, industrial heat resistant, fire resistant, non- hygroscopic DMC material, polycarbonate lens in desired color shades of Red, Green, Amber, Yellow etc. the intensity of light should be minimum 100 mcd at 20 mA. Indicating lamp should be suitable to operate on 30 Volt DC supply source.

13.7 AUXILIARY SUPPLY:- (a) For each Control Panel, the purchaser will provide the following :-

i) 230V (+10% to -20%) single phase 2-wire, 50Hz neutral grounded A.C.supply, frequency variation ±4%

ii) 30V (+ 10% to -15%) D.C. supply (b) H.R.C. fuses shall be provided by the supplier for both the A.C. and D.C. power supplies. (c) All H.R.C. fuses and links shall be with holder; the base of fuse holder shall be mounted on slant

support with identification labels. 13.8 CONTROL WIRING:- (a) The supplier shall provide complete wiring up to the terminal block for the equipment, instrument

devices mounted in the control panel strictly according to the wiring diagram prepared by the supplier based on the purchaser’s information and schematic diagram and get approved from the purchaser.

(b) The wiring shall be complete in all respects so as to ensure proper functioning of control, protection and metering schemes.

don’t All unused potential free contacts of relays and switches if any shall be wired up to the terminal block.

(d) The Control Panels shall be supplied completely wired, ready for purchaser’s external connections at the terminal blocks. For CT circuits, the wiring shall be carried out with 1100V grade PVC insulated stranded copper conductor of size 2.5 sq.mm. For PT and for control circuits the wiring shall be carried out with 1100 V Grade PVC insulated stranded copper conductor of size 1.5 Sq. mm.

(e) Color coded wires should be used to facilitate easy tracing, as under:- i) Three Phase A.C. Circuit: - Red for R Phase, Yellow for Y Phase, Blue for B Phase Black for Neutral,

and Green for earthing.

ii) Single Phase A.C. Circuit:-Red for Phase, Black for Neutral & Green for Earthing.

iii) D.C. Circuit: - Red for Positive, Yellow for Negative.

iv) Control Wiring: - Gray for annunciation and other control circuits.

(f) Each wire shall be identified at both ends with wire designation number by plastic ferrules, as per

wiring diagram based on latest revision of IS-375 to denote the different circuit functions. The supplier shall take approval for the system of wire numbering.

(g) All wire termination shall be made with compression type connectors. Wires shall not be tapped or spliced between terminal points. All wire shall have crimp type termination and direct connection at any place is not at all required.

(h) All series connected devices and equipment shall be wired-up in sequence. Loop-in/loop-out system of wiring shall be avoided, as far as possible and the common buses shall normally be made through the terminal block for better reliability of testing and maintenance.



(i) Fuses and links shall be provided for isolation of individual circuit from the bus wires without disturbing the other circuits and equipments.

(j) The DC trip and DC voltage supplies and wiring to main protective gear shall be segregated from these for back up protection and also for protective apparatus for special purposes. Each such group shall be fed through separate fuses, either direct from main supply fuses or the bus wires.

(k) Since, a number of wires will run from one point to another, it is desired that the support arrangement should be adequate and neat. The conventional method of bunching of wire should not be adopted, since the same may create problems in case any wire is to be removed. The wires should be accommodated in plastic channel with sliding plastic cover mounted inside the panel, suitably. Inspection/removal of wires should be possible by sliding the covers.

(l) Blank plastic channels should be provided by the sides of the panel to accommodate the incoming cables from switchyard through the cable glands.

(m) The circuit diagram of control circuit along with operating instructions (DO/DO’NT) embossed on metallic plate duly laminated shall be provided on rear side of the door.

13.8 TERMINAL BLOCKS:- (a) Multi-way terminal blocks complete with necessary binding screws and washers for wire connections

and marking strips for circuit identification shall be provided for terminating the panel wiring and outgoing cables. The terminal block shall be suitable for receiving at least 2x2.5 sq.mm stranded copper conductor wire per terminal.

(b) Terminal blocks shall have shorting and disconnection facilities. The panel-side and outgoing wires should be disconnectable just by opening the disconnecting links, which slide up/down or left/right without dislodging the wires from their position. However, disconnectable type terminal connectors with shorting facility may be limited to CT & PT circuits only.

(c) Instrument transformer wires shall be terminated through suitably mounted test terminal blocks for site testing facility.

(d) The terminal blocks shall be grouped according to circuit functions and each terminal block group shall have at least 20% spare terminals. Adjacent rows of terminal block shall be spaced not less than 100 mm apart. These shall be mounted vertically at the sides of the cubicle and set obliquely towards rear doors to give easy access of terminating end to enable ferrule number to be read without difficulty. The bottom of terminal blocks shall be spaced at least 200 mm the cable gland of incoming multi-core cables.

13.9 CABLE ENTRY:- (a) The control panel shall have provision of cable entry from the bottom. The box base shall have 3

mm thick cover.

(i) The cover plate of base box for 11 KV and 33 KV MULTI CIRCUIT C&R panels, shall be provided with 3 cable glands for 8 core, 5 cable glands for 4 core and 3 cable glands for 2 core 2.5 sq.mm unarmored copper control cable.

(ii) The cover plate of base box for 11 KV and 33 KV SINGLE CIRCUIT C&R panels, shall be provided with 2 cable glands for 8 core, 2 cable glands for 4 core and 2 cable glands for 2 core 2.5 sq.mm unarmored copper control cable.

The gland plate shall be covered with dummy plate. The bidder has to provide all required material to ensure IP55 protection. The purchaser will arrange for necessary floor opening, below the panel and fixing of gland plate for control cable entry to suit the supplier’s requirement.

(b) The wiring through terminal blocks shall be such located so that it is convenient for floor opening.

(c) For fixing cable glands on the box base cover, detachable gland plates of 4 mm thick shall be mounted at least 100 mm above the floor level.

(d) The cable gland plate and rear door shall be properly rubber gasketted to ensure IP-55 protection.

(e) Rigid supports shall be provided along the terminal block for holding plastic channel. Suitable clamps shall also be provided in plastic channel for holding cables.

13.10 GROUNDING:- (a) 25mm x 6mm x 250mm copper ground bus shall be provided inside the panel for effectively

grounding all metal structures.

(b) Each continuous length of ground bus shall have provision of two terminals at two separate points for connection to main ground grid of the sub-station.

(c) Potential and current transformer neutrals shall be grounded only at the terminal blocks where they enter the control panel from the instrument transformers.



(d) Wherever a circuit is shown grounded in the drawings, a single wire for the circuit shall run independently to the ground bus and connected to it.

13.11 DOORS:-

Each panel shall be complete with end enclosing sheets on both sides and door in the rear. The rear door shall be fitted with handle and also turn twist locks at top and bottom. Proper rubber sealing gasket shall be provided on the door. A type test report from the recognized Government. laboratory or NABL approved lab on degree of protection test IP-55 shall be furnished by the supplier.

13.12 CONTROL AND RELAY PANELS:-

13.12.1 The control panels required for installation at all the sub-stations shall be of simplex type for multi circuit control. The control and indication apparatus, all meters and relays shall be mounted in the front. The instruments and relays shall be flush mounted pattern.

13.12.2 The labeling for the circuits shall be provided at the front control panel, as well as on the inside wall. All indicating instruments, meters and important components shall have identification labels from inside also, in addition to outside. The terminal block shall have identification labels attached to them, clearly indicating type of supply ‘AC & DC identification circuits’ control (metering/protection) and instruments identification. For example, the terminal block shall have an identification indicating that is for CT circuit, metering, protection etc.

13.12.3 A mimic diagram showing single bus arrangement, 700 mm above the box base top with semaphore for breaker position indicator etc. shall be provided for each circuit.

13.14 PROTECTION SCHEME:- 13.14.1 The control panels are required for protection of the following equipments:-

a) 11 KV Overhead sub-transmission lines The protection schemes are described in the following clause:-

13.14.2 Feeder Protection :-

11 KV Feeder Control circuit in the Panel is required for control/protection of 11KV sub-transmission lines. This will be in the form of a IDMT relay having 2 Nos. O/C and 1 No. E/F elements with high set. The current settings of O/C relay element shall be from 2 % to 150% in equal step of 1-2 % each and of E/F relay element from 2 % to 80%. They shall be suitable to work on 30 Volt D.C. supply. The secondary rating of C.T. shall be 5 Amps. The numerical relays having programmable characteristics as per above requirements are required. The relay shall be of draw out type with CT shorting facility. Further, the relay shall have self re-set contacts and hand re-set flag arrangement. The tripping shall be routed through a high speed master trip relay with hand reset facility and flag relay.

13.15.1 CONTROL AND INDICATION CIRCUITS: - 11 KV two feeders (2F): 11 KV multi circuit control & relay panel for control of two feeders shall have

the following instruments, relays and accessories:- Sr N

Particulars 11 KV (2F)

I 3 pole 5 Amp Numeric IDMT relay 30 V DC with self-reset contacts and hand reset flag (Flush pattern) shall be suitable for selecting following settings :- a. O/C Element (2% to 200%) 2 nos. relay each with 2 O/c and 1

E/f element with high set b. E/F Element (2% to 80%) c. Operating Time plug setting With Multiple characteristics

II Pistol grip Circuit Breaker Control switch T-N-C 2 III Digital Ammeter of 96X96.mm size flush pattern CT operated

5 Amp Accuracy class 1.0. 2

(200-100 ) Range 0 to 125 or 250

IV Ampere meter selector switch 2 V Hand Reset Master trip Relay separate for each circuit 2 VI Indicating Lamps

a. CB-ON (RED) 2 b. CB-OFF (GREEN) 2 c. TCH coil-1 2



d. TCH coil-2 2 e. Auto trip 2 f. DC Fail ( separate for each circuit ) 2

VII Push buttons A Alarm accept 2 B Alarm reset 2 c. Pre close Trip Circuit check coil-1 2 d. Pre close Trip Circuit check coil-2 2 E Auto trip 2 f. DC Fail test(Separate for each circuit ) 2

VIII Alarm Bell (DC) 30 Volt DC 1 IX Alarm Bell (AC) 230 Volt AC 1 X Cable glands with dummy cover suitable for 2.5 sq.mm Un-

armored copper control cable fitted on cover plate. 3 nos. for 8 core 5 nos. for 4 core 3 nos. for 2 core

XI Box type base of 100 mm height painted with water resistant black rubber paint complete with 3mm thick cover plate fitted with cable gland box and cover.

1 set

XII Set of Foundation bolts for grouting panel box base with panel 1 set XIII Illumination CFL 11/15 Watt lamp with protective cage &

On/Off Switch. 1

XIV 3 pin-5 A power socket with On/Off Switch. 1 XV MIMIC (10X3 mm) made of Aluminum strip painted black

showing single bus and breaker position semaphore indicator As required

XVI Semaphore CB position indicator 2

13.15.2 A trip healthy lamp shall be provided for each circuit breaker and connected in such a way as to indicate the healthy condition of the trip circuit. The lamp should have the indication on demand when breaker is on. Such indication is also necessary when the breaker is off, but it should be possible to check the trip circuit condition before closing the circuit breaker. In brief, pre and post close trip supervision facility on demand is required and shall be included. 13.15.3 The automatic tripping of the circuit breaker due to operation of protective relays shall be indicated by a common audible DC alarm. The DC fail alarm shall be indicated by a common audible AC bell for each of the multi circuit panel 13.15.4 The bidders are required to submit C&R panel general arrangement and schematics indicating all relevant details of all relays and gadgets along with bill of material. 13.15.5 The mimic of 10X3 mm thick Aluminum strip painted black showing single bus arrangement and breaker position semaphore indicator shall be provided 700 mm above the box type base channel on each C&R panel. NOTE: Any other indications or control equipments which are required for proper protection/ operation of circuit breaker should be provided in control panel, without any extra cost. 13.16.0 RELAYS:- 16.1 All relays, except where otherwise approved, shall be capable of breaking the maximum current which shall not be affected by vibration or by external magnetic fields. The contacts shall be of silver, platinum or other better materials and shall be suitable for efficient and reliable operation of protection scheme. 16.2 All relays /auxiliary relay, which are connected to complete the tripping circuit of the breaker coil, shall be provided with approved flag indication, which whenever possible shall be mechanically operated type. Indicators shall also be provided on such additional relay elements as it will enable identification the type & phase of fault condition to be identified. Each indicator, whether of the electrically or mechanically operated type, shall be capable of being reset by hand, without opening the relay case. Each indicator shall be so designed that it can not move before the relay has completed its operation. It shall not be possible to operate any relay by hand without opening case. 16.3 All relays shall be so arranged that on opening the case it shall be impossible for any dust which may have collected in or upon the case to fall on the relay mechanism. 16.4 The numerical Over current and earth fault relays shall have inverse definite minimum time limit having programmable characteristics as per above requirements. Further, these relays shall have self reset contacts with hand reset flag arrangement. The relay rating shall be 5 Amps.

13.17.0 INSTRUMENTS:- 13.17.1 All indicating instruments shall conform to IS-1248 and shall be of type and sizes specified in GTP. They shall be capable of carrying their full load currents continuously without heating. They shall



have long clearly divided and indelibly marked scales of engraved or enameled and the pointers shall be of clean outline. The design of pointers and scales shall be got approved. The marking on the dials shall be restricted to the scale marking. All indicating instruments, shall be provided with non-reflecting glass type fronts. All indicating instruments shall be of class 1.0 accuracy. 13.17.2 The bidders shall arrange to furnish type test certificate for Ammeter and Voltmeter and all relays along with the bid. 13.17.3 It may be carefully noted by the Bidder that automatic tripping of the circuit breaker due to operation of protective relay shall be indicated by audible alarm. The offered alarm scheme shall be complete in all respects including one DC bell for trip alarm with a contactor/ auxiliary relay suitable to handle breaking of DC bell current. The contactor/auxiliary relay will get energized through the self reset alarm contacts of protective relay and will remain actuated by its own seal-in contact. A push button shall be provided to accept alarm by breaking the seal in contact. It may also be noted that they should organize services of their engineer at any site if any problem is reported either by the purchaser or field units. 13.18 TESTS:- 18.1 Each control panel shall be completely assembled, wired, adjusted and tested at the factory, prior

to dispatch. 18.2 The tests shall include wiring continuity tests, insulation tests and functional tests to ensure

operation of the control scheme and individual equipment. 18.3 The test procedures shall have prior approval of the purchaser. 18.4 All instruments, meters and relays shall be tested and calibrated in accordance with relevant

standards. 13.19 TEST CERTIFICATE:- Each control & relay panel should be tested by the manufacturer at their works for all routine and acceptance tests and copies of test certificate in duplicate giving results of these tests shall be furnished to the purchaser along with letter / offer for inspection.

13.20 TEST WITNESSING:- The routine/ acceptance tests results shall be witnessed by purchaser’s representative, if so desired by the purchaser, prior to dispatch of the equipment from the works. The supplier shall give at least Fifteen (15) days advance notice of the date when the tests are to be carried out.

13.21 TEST CERTIFICATE OF COMPONENTS:- Test certificate for important components like Ammeter, Voltmeter, Relays and Control Switch shall be produced at the time of inspection and shall be enclosed with the inspection report.

13.22 PRE-TREATMENT AND PAINTING PROCESS:- The Control Panel sheet steel shall be subjected to pre-treatment process before painting. The process shall be carried out as under. The procedure can broadly be divided as “Metal treatment” and “painting”.

(A) METAL TREATMENT:- i) DEGREASING :-

This can be achieved either by immersing in hot alkaline degreasing bath or in hot di-chloro-ethelene solution. In case degreasing is done by alkaline bath, rinse with cold water thoroughly.

ii) PICKLING :- This is to remove rust and metal scales by immersing in diluted sulphuric acid (approximately 20%) at nearly 80 degree centigrade until scale and rust are totally removed.

iii) Rinse in cold water in two tanks to remove traces of acids. iv) Treat with phosphoric acid base neutralizer, for removal of chlorine from the above acid pickling and

again wash with running water. v) PHOSPHATING :-

Immerse in grenadine Zinc phosphate solution for about 20 minutes at 80 to 90 degree centigrade. The uniform phosphate coating of 4 to 5 gms per sq. meter shall be achieved.

vi) Swill in cold water. vii) Rinse in deorylyte bath at 70 to 80˚C to neutralize any traces of salts. viii) Seal the above phosphate coating with hot dilute chromate solution. ix) Dry with compressed air. (B) PAINTING:-

Sequence of process shall be as follows:



i) Spray one coat on wet surface by specially developed, “High Luster” Zinc chromate primer and stove at 150 to 160 degree centigrade for 25 to 30 minutes. Alternatively, Red-Oxide primer with zinc chromate content may be used. However, former process is preferred.

ii) Rubbing and putting: - Apply putty to fill up the scar, if any, to present smooth surface and stove 15 to 20 minutes. Apply putty several times to get the perfectly smooth finish.

iii) Surfacing:- Sand down with mechanical abrasive and stove for 20 minutes.

iv) Primer:- Spray second coat of primer as per (i) above or grey primer surface on wet and stove for 30 to 40 minutes at 150 degree centigrade.

v) Finish Paint: - Rub down dry and spray first coat of synthetic enamel finish paint on wet and stove for 30 minutes.

vi) Surfacing:- Sand down or rub dry to prepare for final finish. Spray 2 coats of synthetic enamel finish paint on wet and stove it at 150 degree centigrade for 30 minutes.

NOTE:- i) Necessary stiffeners may be welded between large cut outs to provide rigidity before painting process.

ii) Painting process shall be done within 24 Hrs. of completion of metal treatment.

iii) Small coating shall be supplied along with equipment for touching up at site.



SCHEDULE-III GUARANTEED TECHNICAL PARTICULARS OF MULTI CIRCUIT 11 KV FEEDER CONTROL &

RELAY PANELS Sr. No

Particulars Provisions

1 Dimension H x D x W (1475 X 300 X 600 mm) 2 Thickness of steel sheet in mm (minimum 2mm) 3 Arrangement of rear door(Provision of turn twist locks at top &

bottom with handle)

4 Interior illumination (CFL with protective cage & On/Off switch)

5 Provision of detachable Gland Plate (4mm thick at 200 mm above base of the panel)

6 Make, Type & Rating of Terminal Connector for CT/PT circuits (dis-connectable type)

7 Make, Type & rating of Terminal Connectors for control circuits (Non-disconnecting type)

8 Provision of Spare terminal connectors (20%extra) 9 Size of conductor used for Wiring of CT, PT circuits & control

circuits (2.5 sq.mm stranded copper for CT, PT circuits & 1.5 sq.mm for other circuits )

10 Wiring colour codes for R,Y, B Phase & Black Neutral (AC), Red- Positive, yellow-Negative(DC), Green-Earthing, Grey- control circuit

11 Instruments identification (labels to be provided) 12 CT/PT/AC/DC/ Circuit Identification (labels to be provided) 13 Final outside finish (Opaline green color) 14 Inside finish(Egg shell white) 15 Make, Type, scale of Ammeter (96 Sq.mm. Flush Mounting Type

Dual Range, 5A, 0 to125 or 250V

17 Make & Rating of Ammeter Selector switch (current rating shall not be less than 15A)

18 Type & thickness of gaskets provided in the rear door & cable gland plate

19 Make, Type & Rating of Breaker controls switch

20

IDMT O/C and E/F Relays:- Feeder Control (numerical) with high set

i. Make ii. Model no.

iii. O/C Setting

iv. E/F Setting

v. IDMT

vi. Configuration (Horizontal)

vii. Total nos. of NO and NC Contacts(Hand/self reset) viii. Hand or Self Reset Flag

21 Make, Type & Rating of Pistol grip breaker control switch 23 Make, Type & Rating of indicating lamps & Total nos. of lamps

24 Make, Type & Rating of Push Buttons & Total nos. of PBs.

25 Make, Rating of HRC Fuses & Total nos. of fuses (Rating wise) 26 Provision of copper Earthing Bus (25mm x 6 mm x 250 mm)size 27 Provision of Alarm cancellation relay (Give Make, Type, Rating)

28 Type of wire termination to terminal blocks & instruments (Crimp tag/lugs termination)

29 Provision of Plastic Channels with sliding covers for wiring 30 Provision of Spare Plastic channels with sliding cover

31 Ferruling of wires at both ends

32 Provision of 3-Pin 5A Socket with On/off switch 33 Provision of lifting Eye-Bolts & their size 34 Provision of circuit diagram on rear side of back door of the panel 35 Provision of Pocket with adequate space with transparent cover on

top of panel for identification name of feeder / transformer panel.

36 Provision of engraved rating plate



14.0 TECHNICAL SPECIFICATION FOR 11 KV OUTDOOR TYPE EPOXY MOULDED DRY CURRENT

TRANSFORMERS

14.1 SCOPE: This specification covers design, manufacturing, testing, inspection before dispatch at manufacturers works and delivery of 11 KV Outdoor Single Phase, Epoxy Molded Dry type Current Transformers for relaying and metering services in 11 KV solidly grounded system.

14.2 GENERAL REQUIREMENT:-

14.2.1 11 KV current transformers shall be of outdoor type, single phase, epoxy molded, dry

type design and suitable for operation in humid atmospheres and in the tropical direct sun-light with temperature up to 50 degree centigrade.

14.2.2 The above CTs should be suitable for use in areas subject to heavy lightning storms.

The CTs should be suitable for operation under the climatic conditions, prevailing in the State of M.P.

14.2.3 Further, the above CTs are required to be mounted on an out door structure in the

switchyard. CTs will therefore, have suitable mounting holes at the base channel, for clamping it on the structure.

14.2.4 The current transformers shall have the following specification :- s.n. Particulars 11 KV i Nominal system voltage 11 KV ii Highest system voltage 12 KV iii Frequency 50 cycles iv Earthing of the system Effectively grounded v Insulation level 28/75 KV vi Short circuit level 250 MVA vii Minimum one second short time current rating 13.1 KA viii Minimum creep age distance 300 mm ix Rated secondary current 5 Amps x Tank sheet thickness Minimum 3mm xi CT Ratio

200-100/5-5 Amps

300-150/5-5 Amps xii No. of cores (with the following accuracies) 2

Core Core-I Core-II Purpose Relaying/ Metering Protection Rated output 15 VA 10 VA

Accuracy class 10P10 1.0

14.3 DESIGN: 11 KV CT after providing insulation between core and windings shall be molded in epoxy compound and thereafter shall be housed directly in the tank. Thickness of steel tank sheet shall not be less than 3 mm. Welded joints have to be minimized. In any case welding in horizontal plane shall be avoided.

14.4 STANDARDS:- The current transformers shall comply with the latest issue of Indian Standard 2705 (Part-I, II, III &

IV) or IEC-185 with latest amendment thereof.

14.5 GENERAL:

14.5.1 The 11 KV current transformers shall be outdoor single phase, epoxy molded dry type suitable for the services indicated, complete in all respect conforming to the modern practices of design and manufacturing.

14.5.2 The core shall be of high grade, non-ageing electrical silicon laminated steel of low hysterisis loss and high permeability to ensure high accuracy at both normal and over-currents.

14.5.3 The current transformers shall be sealed properly to eliminate and prevent air, moisture from entering the tank. For gasketted joints, whenever used, nitrite butyl rubber gaskets, neoprene or any other improved material shall be used.

14.5.4 The maximum temperature attained by any part of the equipment, when in service, under continuous full load conditions and exposed to direct rays of sun, shall not exceed 45 degree centigrade above ambient.



14.5.5 The primary winding, terminals, terminal connectors clamps etc. are required to be designed considering the continuous over loading of 25 percent. For 25 percent continuous over loading, the ratio and phase angle error shall be maintained within the specified limit applicable for normal loading conditions. Further, temperature rise for 125 percent loading shall be within the permissible limits specified in the relevant IS.

14.6 WINDINGS: 14.6.1 The current transformers core to be used for metering and instrumentation shall be of

accuracy class specified in Clause 2.4 (xii) above. The primary winding shall be designed considering current density not exceeding 1.5 Amps/Sq.mm. The saturation factor of this core shall be low enough not to cause any damage to measuring instruments in the event of maximum short circuit current.

14.6.2 Current transformer cores to be used for protective relaying purposes shall be of accuracy class specified or appropriate class suitable for over current protection. The cores shall be designed for a minimum saturation factor of 10 for the highest setting. The magnetization curves for these cores shall be furnished along with the drawings of CTs.

14.6.3 The rating of the secondary windings shall be 5 Ampere. For secondary connections, threaded studs terminal shall be provided and brought out in a compartment on side of current transformer for easy access. Further, the secondary terminals shall be provided with short circuiting arrangement. The secondary taps shall be adequately re-enforced to with-stand normal handling, without damage.

14.6.4 Secondary terminal studs shall be provided with at least three nuts and adequate plain and spring washers for fixing the leads. The studs, nuts and washers shall be brass nickel plated. The minimum outside diameter of the studs should not be less than 6 mm. The length of at least 15 mm shall be available on the stud for inserting the leads.

14.6.5 The CT secondary terminals shall be brought out to a suitable weather proof sheet metal terminal box for termination of multi core cables. The terminal box shall be provided with two nos. cable glands suitable for 4 core 1100 Volt grade, PVC Insulated 2.5 sq.mm. Copper Cable. The dimension of terminal box and its opening shall be adequate to enable easy access and working space with use of normal tools. The outer cover of the secondary terminal box shall have proper arrangement of sealing.

14.7 INSULATION:- 14.7.1 The current transformers shall be single phase, multi core, separately

mounted, free standing type for outdoor installation.

14.7.2 The insulators shall be prepared from wet process porcelain with arrangement for sealing hermetically the metallic tank containing the core and the secondary winding.

14.7.3 The primary terminals of current transformer shall be of non-ferrous corrosion-proof material and shall be provided with suitable terminals connectors to receive ACSR Dog Conductors.

14.7. The terminals of primary and secondary winding shall be clearly marked according to relevant standards.

14.8 INSULATION WITH STAND CHARACTERISTICS:- 14.8.1 Insulation withstand characteristics of 11 KV CTs shall be as per IS:2705 as shown in

the table below :-

Nominal system voltage

Highest system voltage

Power frequency withstand Voltage (for 1 minute)

Lightning Impulse withstand Voltage (for 1 minute)

11 KV (rms) 12 KV(rms) 28 KV(rms) 75 KV (peak)

14.8.2 The exterior of the CT tank shall be thoroughly cleaned, scraped and giving a primary coat and two coats of durable oil and weather resisting enamel paint or hot dip galvanized. All steel bolts, nuts and fasteners exposed to atmosphere, shall be hot dip galvanized conforming to IS: 2633.

14.8.3 Change in CT ratio will be obtained by providing tapings in the secondary windings, while the primary will have only one winding.

14.8.4 The CTs are required only of outdoor type having fitted with outdoor type porcelain bushings. Compound filled CTs are not acceptable. The CTs will be dead tank design and live tank design CTs are not acceptable.



14.9 TYPE OF MOUNTING: The CTs shall be mounted on CT bracket, provided on Circuit Breaker’s structure.

14.10 TERMINAL CONNECTORS:- The terminal connectors required for connection of the current transformer to owner’s

equipment/ bus shall be in Bidder/manufacturer’s scope. The terminal connector shall be suitable for DOG AAAC Conductor. The terminal connector shall be conforms to latest version of IS: 5561 or equivalent International Standard. In respect of the terminal connector following shall be ensured:-

(i) All current transformers shall be provided with terminal connectors suitable to receive on Raccoon/Dog AAAC conductors. Clamps shall be designed adequately to take care of any bimetallic effect. Terminal connectors shall be tested for short circuit current capability, temperature rise.

ii) The terminal connector shall also meet the following requirements :- a) Terminal connectors shall be manufactured & tested as per IS: 5561. b) All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges

and corners shall be blurred and rounded off. c) No part shall be less than 12 mm thick. d) The nuts, bolts & washers used in the current path shall be stainless steel. e) The bimetallic strips/ sleeve liner of minimum thickness of 2 mm shall be cast integral with

Aluminum body. f) All current carrying parts shall be designed and manufactured to have minimum contact

resistance. g) The terminal connectors should be made of A6 Aluminum Alloy and manufactured by gravity

die-casting process only. Sand die-casted connectors are not acceptable. h) Size of terminal connector for which the clamp is designed and also rated current under site

conditions shall be embossed/ punched on each part of clamps, except hardware. i) The conductor shall be tightened by at least four bolts. Conductor hold length must not be less

than 60 mm. j) The surface of clamps to be tightened by the bolts should be flat in shape,so that it may be

possible to open the nuts and bolts by normal spanners. Therefore, any type of groove in the clamp body for fixing of nuts should be avoided.

k) The portion of clamp to hold the conductor should be flat and straight and not zigzag in construction, at both the sides, so that heating of clamp by throttling action of current may be avoided.

l) Space of at least 50% of diameter of nuts should be available after hole at both the sides of conductor holding portion for better mechanical strength.

Each CT shall be provided with two separate terminals for bolted connection to 50x8 mm. MS flat.

14.11 STUDS: Length of the primary studs available for clamping terminals shall not be less than 50

mm. Minimum 2 nuts with a check nut and washer should be provided on upper side of stud. Minimum size of stud should be 12 mm for 200-100/5-5 Amps and 16mm for 300- 150/5-5 Amps CTs. Further, the primary studs shall be so designed as to have current carrying capacity of at least 1.5 times that of the primary winding.

14.12 BUSHING: Basic insulation level of the bushing shall be as specified and porcelain shall be

homogenous and free from cavities and other flaws. This shall be so designed as to have ample insulation and mechanical strength. All insulators of identical ratings shall be inter-changeable. The type tested insulators shall be provided in the CT.

14.13 TESTS; (I) Short time current ratings:-

Out door type CTs shall comply with the following requirements in respect of short time current ratings:-

a) Thermal Ratings: Short time thermal current rating assigned to the CTs for the rated time of 1 second shall be 13.1 KA.

b) Dynamic Rating:



Peak value of the rated dynamic current which CT can withstand without being damaged electrically or mechanically with the secondary winding short circuited shall not be less than 2.5 times the rated short time thermal current.

(II) Temperature Rise

Temperature rise of the CTs of outdoor type when carrying a primary current equal to continuous thermal current, at a rated frequency and at a rated burden, shall not exceed 45˚C above ambient.

14.14 TESTS: (A) TYPE TEST:-

CTs shall be fully type tested for the following tests as per IS-2705/1992 with latest amendment thereof from independent NABL accredited Laboratory. Type test certificates of CT with type tested drawings duly sealed and signed by the Testing Authority should be submitted within twenty eight days of the date of Notification of the Award. a) Short time current tests. b) Temperature rise test. c) Lightning Impulse Voltage withstand test. d) High voltage Power Frequency wet withstand voltage tests e) Determination of errors according to the requirements of the appropriate accuracy class.

(B) ROUTINE TESTS:-

Each CT shall be subjected to following routine tests as per Indian Standard 2705 at the manufacturer works and test reports in duplicate giving results of these tests shall be submitted for the Employer’s approval before dispatch of the equipment. Further, above test results shall be witnessed at the manufacturer works, if so desired by the Employer, prior to dispatch of the CTs:-

a) Verification of terminal markings and polarity b) Power frequency dry withstand tests on primary windings c) Power frequency dry withstand tests on sec. windings d) Over-Voltage inter-turn test e) Determination of errors according to the requirements of the appropriate accuracy class f) Partial discharge test

14.15 In case of any change in design/ type of CT already type tested, are offered against this specification, the Employer reserves the right to demand repetition of some or all the tests without any extra cost at NABL accredited Laboratory. 14.16 RATING PLATE:

CT shall be provided with a rating plate with dimensions and marking as per the latest version of IS:2705/IEC-185. Marking shall be punched/ engraved and not painted. This rating plate shall also contain the Employer’s order no. & date, month & year of dispatch.

GUARANTEED TECHNICAL PARTICULARS OF 11 KV CURRENT TRANSFORMRS S.N. Particulars 11 KV

1 Manufacturer’s name & place of manufacturing

2 Manufacturer’s type designation of CT

3 Rated Voltage (KV) 4 Rated Primary Current (Amps)

5 Rated Secondary Current (Amp)

6 Short time thermal current for 1 sec. (KA)

7 Rated Dynamic Current (KAp)

8 Frequency (Hz) 9 Insulation level (KV/KVp) 10 Number of cores 11

Epoxy composition (i) Resin:-



(a) Make

(b) Type

I Ratio, process of making (Hot or Cold)

(ii) Filler:-

(a) Make (b) Type

I Ratio process of making (Hot or Cold)

(iii) Hardener:-

(a) Make

(b) Type I Ratio process of making (Hot or Cold)

12 Weight of CT after epoxy molding

13

(A) Metering Core:-

(i) Rated Burden (ii) Class of accuracy

(iii) ISF

(B) Protection Core :-

(i) Rated Burden (ii) Class of accuracy (iii) ALF (iv) Knee point voltage(Min)

(v) Secondary limiting EMF

(a) Lower Ratio (b) Higher Ratio

(vi) Composite error

(a) Lower Ratio

(b) Higher Ratio

(vii) Exciting current (A)

(a) Lower Ratio

(b) Higher Ratio

(viii) Secondary Winding resistance at 75 ºC

(a) Lower Ratio

(b) Higher Ratio

14 No. of secondary turns/cross section

15 No. of primary turns/cross section

16

Winding material:-

(i) Primary

(ii) Secondary

17 Rated continuous current



18 Class of insulation

19 Thickness of sheet steel enclosure of CT

20 Total weight of CT with enclosure

21 Weight/Qty. of oil used N.A. 22 Dimensions of CT:-

(a) Length

(b) Width (c) Height

23 Size of base channel 24 Vertical height between bottom of the

terminal to the base of the mounting plate

25 Provision of 2 nos. Bimetallic Terminal connector suitable for AAAC Dog conductor.

26 Size of Primary and Secondary studs

27 Make of HV bushing & its creep age distance



15.0 TECHNICAL SPECIFICATION OF 11KV OIL IMMERSED CT/PT (METERING EQUIPMENT) UNITS

15.1 SCOPE: -

This specification covers design, engineering, manufacture, testing and inspection before dispatch and delivery.

15.2 The specification covers Oil immersed naturally Air cooled (type ONAN) outdoor type 11 KV metering equipment (ME) units which shall comprise 3 nos C.Ts conforming to IS-2705: 1992 and 1 no three phase PT conforming to IS: 3156:1992. 11 KV ME units shall be suitable for 50 Hz frequency & for service under the system conditions having frequency fluctuations of +/- 4% and voltage fluctuation of + 9% / -13.5%.

15.3 STANDARDS:

The 11 KV oil immersed CT: PT (metering equipment) Unit and the associated accessories shall conform in all respect to the following relevant standard specification, with latest amendment thereto:

15.4 CLIMATIC SERVICE CONDITIONS:

The 11 KV oil immersed CT/ PT (metering equipment) unit to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot, cold, tropical and dusty climate and solar radiation typically existing in the State of M.P. 11 KV CT/ PT (metering equipment) Unit shall be required to operate satisfactorily and continuously under the following tropical climatic conditions:

(a) Maximum ambient air temperature 50oC (b) Maximum ambient air temperature in shed 45oC (c) Maximum temperature attainable by the ME exposed to sun 85oC (d) Minimum ambient temperature (-) 5oC (e) Average daily ambient air temperature 40oC (f) Maximum relative humidity 95% (g) Number of months of tropical monsoon condition 4 months (h) Maximum altitude above mean sea level 1000 m (i) Average annual rain fall 150 cms (j) Maximum wind pressure 150 kg/sq.m (k) Isoceraunic level (days per year) 50 (l) Seismic level (horizontal accn.) 0.30 g (m) Permitted noise level 45.db

All the parts & surface, which are subject to corrosion shall either be made of such material or shall be provided with such protective finish, which provides protection from any injurious effect of humidity.

15.5 PRINCIPAL PARAMETERS:

11 KV combined CT/PT (ME) units shall be suitable for 50 Hz frequency & for service under the system conditions having frequency fluctuations of +/- 4% and voltage fluctuation of + 9% / -13.5%. CT/ PT (metering equipment) units shall be hermetically sealed and suitable for service under the system conditions as per following specific parameters:

Sl. No.

Particulars Parameters

1. Type of installation Outdoor 2. System frequency 50 Hz ±4% 3. Normal System Voltage 11KV

Indian Standard specification

Title

IS 2705: 1992 Specification for Current Transformer IS: 3156:1992 Specification for Voltage Transformers IS: 335:1983 Specification of Transformers Oil IS: 2099:1986 Specification for bushing for AC voltage above 1 KV IS:5561 Specification for terminal connector IS:4201 Application guide for current Transformer



4. Highest System Voltage for substantially long period

12KV

5. System voltage fluctuations + 9% & -13.5%. 6. System earthing Solidly grounded

15.6 TECHNICAL REQUIRMENT:

The 11 KV oil immersed combined CT:PT (metering equipment) units shall conform to the following specific parameters

S. no.

Particulars Requirement

1 Frequency. 50 HZ 2 Specification of CT and PT of Metering Unit A Current Transformer

i CT Ratio As per schedule I(B) ii Dual CT ratio for Energy Audit 300-150/5A iii Accuracy Class 0.5 iv VA burden 10 VA v Power Frequency withstand voltage 28 KV(rms)

vi Lightning impulse with stand voltage 75 KV (peak) vii

Short time thermal current rating in KA. 13.1 KA for 2 Sec for dual ratio.

B Potential Transformer (VT) i. PT ratio 11KV/√3

110V/√3 ii VA burden per phase 30 VA iii Class of accuracy 0.5 iv Power Frequency withstand voltage 28 KV (rms)

v Lightning impulse with stand voltage 75 KV peak vi Winding connection Star/ Star

3 Maximum attainable winding temperature 85° C

4 a Minimum phase to phase distance 255mm b Shortest distance between metal part & earth 190 mm c Creep age distance of HV bushing 300mm (Min)

5 Gauge of the MS tank - Min 5 mm for top cover and bottom - Min 3mm for tank sides

6 Bi-metallic terminal connector with a nut, plain washer, spring washer & check nut suitable for Rabbit AAAC conductor.

6 nos to be provided

15.7.1 11 KV combined metering equipment unit shall comprise of 3 nos. CTs conforming to IS-2705:

1992 and should not exceed the current ratio error and phase displacement error as prescribed therein and 1 no. three phase PT conforming to IS-3156: 1992 and should not exceed the ratio error and phase replacement as prescribed therein. The oil characteristics shall be conforming to IS-335: 1983 & with latest amendments and upgrade, if any. The CT secondary winding shall be suitable for transformer oil filled equipment.

15.7.2 Primary of PTs shall be 3 phase star connected with HV side neutral floating. The primary winding has to be designed for unearthed neutral for the highest system voltage i.e. 12 KV for 11 KV. PT winding should have uniform insulation throughout from terminal to neutral end, and not the graded insulation. The 11 KV metering unit should be suitably designed for with-standing the unbalanced voltages developed due to single phasing operation during load regulatory measures in 11KV distribution system. It should be capable of withstanding the disturbance of back e.m.f., magnetic characteristic and consequential mechanical inter-play of forces, if any, under such single phasing. Secondary winding of PT should be three phase star connected with neutral brought out. On secondary side of PT four terminals shall be marked as r, y, b and n. No PT fuses are to be provided either on primary side or on secondary side.

15.7.3 Conductor in secondary winding of the CT shall not be less than of 14 SWG/3.24 sq.mm. 15.7.4 Normal current density shall not be more than 1.5 Amps/ sq.mm. in primary winding of the CT.



15.7.5 Primary winding shall be of adequate cross section to carry continuously rated current plus

20% overload. 15.8 TANK 15.8.1 Metering equipments shall be contained in a weather proof out door double pole mounting type

M.S. tank with 6 nos. of 11 KV weather proof bushings with brass studs as per rating of combined CT: PT (metering equipment) units.

15.8.2 3 nos. bushings on incoming and 3 nos. bushings on outgoing terminals i.e. (mains side & load

side), with M and L marking embossed on the top cover of MS tank to identify incoming and outgoing terminals of the metering unit, shall be provided.

15.8.3 Tank should be given three coats of rust preventing paint and finished with light grey No.631-IS-

5 on all external surfaces. The internal surface of the tank shall be painted with two coats of a suitable oil-insoluble paint.

15.8.4 ME shall be supplied complete with duly filled transformer oil conforming to IS:335–1982 with

latest amendment thereof. Test certificate of oil being used shall be provided at the time of inspection. Oil in the ME shall be filled under vacuum. Oil drain valve or sampling cock or non return type oil filling valve provided to facilitate factory processing shall be sealed before dispatch of MEs.

15.8.5 ME shall be hermetically sealed and shall be provided with a oil conservator, having oil level

gauge, of adequate size to facilitate expansion/contraction of oil due to change in temperature. Total volume of conservator shall be such as to contain 10% quantity of the oil. Normally minimum 3% quantity of the total oil shall be contained in the conservator. The volume above the oil level in the conservator tank shall be filled with Nitrogen gas conforming to commercial grade as per IS:1747:72.

15.8.6 A pressure release safety device suitable for operation at a pressure of 0.4 to 0.5 Kg/sq.cm.

shall be provided at the top of the conservator tank 15.8.7 An explosion vent diaphragm shall be provided opposite side of the ME secondary terminal

box which should operate at a pressure of 0.6 to 0.8 Kg/sq.cm. The Bidder/manufacturer has to produce the test/calibration certificate for proper operation of the device at the defined pressure.

15.8.8 Pressure of Nitrogen gas, pressure release device and explosion vent diaphragm shall be

properly coordinated. 15.8.9 ME shall be fitted on HV side with outdoor type porcelain bushings of appropriate voltage &

current and shall conform to IS:2099:1986. Further, sealing arrangement shall be such that oil should not leak out from the bushing/ME tank. For gasketed joints, wherever used, nitrite butyl rubber gaskets/neoprene or any other improved material shall be used. Gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression. It should be ensured that the quality of gaskets used between the joints and also for mounting of oil level indicator will be of best quality to avoid leakage of oil. The quality of gasket should be selected keeping in mind the ambient temperature of 50ºC. The end turns insulation of PT HV winding towards bushing side should be appropriately enhanced. The dimensions and electrical characteristics of the bushing shall be in accordance with relevant ISS and its subsequent amendments, if any. Minimum electrical clearance between phases and phase to earth shall be provided as specified in relevant ISS.

15.8.10 Insulating materials for winding between HV & LV between interlayer of the winding and for

end turn shall be as per relevant ISS. However, end turns have to be provided with enhanced insulation and lead connecting bushing shall be provided extra insulation of fiber glass sleeve.

15.8.11 Metering equipment shall have a built-in secondary terminal box. Entry of cable into the box on

the dual ratio metering unit shall be through one no. gland & check nut. Metallic cable gland to suit 12 core 2.5 Sq.mm armored copper cable shall be supplied with ME.

15.8.12 For Dual ratio MEs, the secondary box may be provided on side wall of the tank with side cover. Ratio changing arrangement (for dual ratio ME only) should be provided on secondary



side. Top of the tank will have slope to drain the rainwater. Fixing of conservator on the top cover of metering unit shall be such as to avoid collection of air pockets inside tank.

15.8.13 Top cover flange of metering unit should be provided with holes for proper sealing

arrangement at all four corners of the tank and cover. Secondary terminal box cover should have 8 nos. nuts & bolts with hole for sealing arrangement. For this, 8 nos. holes should be provided on the cover & flange of secondary terminal box at the corners & middle of each face for fixing nut bolts.

15.8.14 Metering unit shall be provided with non-detachable anodized Aluminum name plate showing

position of terminals, their marking, connection diagram along with the information as specified in IS: 2705 and IS: 3156 i.e. type, voltage ratio, CT ratio, rated burden, class of accuracy, sr. no. of unit, order no. & date, month and year of dispatch etc. of metering unit. Further, MS plate size 125 x 125 mm is got welded on wider side of metering unit for fixing of the nameplate.

15.8.15 gaskets used should be of best quality having a thickness of 3 mm or more. Information about

gasket material used for the metering unit should be mentioned in the offer. Tank shall be of robust construction having thickness of top and bottom sheet of minimum 5mm and all the sides of tank made up of minimum 3 mm sheet. Welded joints of the metering unit shall be strengthened by providing 25 x 25 x 3mm angle all along the welded length and welded properly inside the tank. All joints of the tank and fitting shall be oil tight. The tank shall be reinforced by welded angle of size 25 x 25 x 3mm on the entire outside wall on the edge of the tank to form two equal compartments. One face of reinforcement angle should be continuous welded with the tank surface such that other side of the angle forms inverted "L".

15.8.16 Mounting of the bushing on the metering equipment should be in oblique plane particularly in

case of single ratio metering unit. CT primary and secondary terminals shall be marked clearly as indicated in Annexure-C of IS: 2705, the terminal marked P1 of primary and S1 of secondary in case of current Transformer and correspondingly in case of PT shall have the same polarity at any instant.

On secondary side of PT, four terminals shall be marked as r, y, b and n. The metering unit

shall have the following: (i) Riveted Rating and Diagram plate. (ii) 2 Nos. welded lifting lugs of MS plate 4 mm thick. (iii) 2 Nos. base mounting channels size 75 x 40 mm across length of metering unit. (iv) 2 Nos. earthing terminals with lugs. (v) Provision of 6 nos. Bi-metallic clamps suitable for AAAC Rabbit conductor for 11 KV.

The terminal connector shall conform to the latest version of IS:5561. In respect of terminal connectors following should be ensured.

a. Terminal connector should be made of A6 Aluminum Alloy and manufactured by

gravity die-cast. b. All castings shall be free from blow holes, surface blisters, cracks and cavities. All

sharp edges should be rounded off. c. No part of clamp shall be less than 12 mm thick d. Bimetallic strips/sleeves shall be minimum 2 mm thick e. All nuts/bolts/washers shall be of stainless steel. f. Conductor should be tightened by minimum 4 bolts. Conductor hold must not be less

than 50 mm. 15.9 Earthing:

The assembly comprising of chassis, frame work and the fixed parts of the metal casing of the combined CT:PT metering equipment shall be provided with two separate earthing terminals in accordance with clause 5.2 of IS:3156 (part-I).

15.10 TESTS: 15.10.1 TYPE TEST The design of metering unit shall be type tested for short time current test, temperature rise test, lightning impulse test, accuracy test, high voltage power frequency voltage withstand test as per IS-2705/1992 and IS-3156/1992 (with latest amendment) from CPRI, ERDA or any other NABL accredited lab. The test certificates should not be more than three years old on the date of opening of tender.



15.10.2 ROUTINE TEST

Each of completely assembled metering unit shall be subjected to the following routine tests at the manufacturer’s works in accordance with the details specified in IS:2705 and IS:3156:-

a. Verification of terminal marking and polarity test of CT and PT of metering unit b. Power frequency dry withstand test on primary winding of CT and PT of metering unit. c. Power frequency dry withstand test on secondary winding of CT and PT of metering

unit. d. Over Voltage inter turn test on CT of metering unit. e. Determination of errors or other characteristics according to requirements and class

of accuracy of CT and PT of combined Metering Equipment. f. Induced voltage test on PT of metering unit. g. Break down voltage test of transformer oil. h. Pressure test on tank of metering unit at 0.8 kg./ sq.cm. i. Ratio & phase angle error test of CTs of metering unit. j. Insulation Resistance test with 1 KV megger.



GUARANTEED TECHNICAL PARTICULARS OF OUTDOOR OIL IMMERSED 11 KV CT: PT (ME) UNITS.

S. no

Particulars Requirement Offered

1 Nominal System Voltage 11 KV 2 Highest System Voltage 12 KV 3 Frequency. 50 HZ 4 Specification of CT & PT of Metering Unit A Current Transformer

i Type Oil immersed ii Accuracy Class 0.5 iii Rated output 10 VA iv Insulation level 28KVrms/

75 KVpk

v

Short time thermal current rating 13.1KA for 2 second

vi Saturation factor To be indicated vii Normal current density of primary

winding 1.5 Amps per Sq.mm

B Potential Transformer

i Type Oil immersed ii PT ratio 11 KV/√3

110V/√3

iii Rated output VA/phase 30 iv Class of accuracy 0.5 v Insulation level 28KVrms/

75 KVpk

vi Winding connection Star/ Star vii Rated voltage factor & duration To be indicated

5. Dimension of MS tank a Height mm To be indicated

b Breadth mm c Length mm

6. Thickness of MS Tank Side walls, Top, Bottom

To be indicated

7. Weight of core and winding

A. Current transformer i Core To be indicated ii Primary winding iii Secondary winding

B. Potential transformer i Core To be indicated

ii Primary winding iii Secondary winding

8. Quantity of oil in KL To be indicated 9. Total weight of complete metering unit

including all accessories and oil To be indicated

10 Resistance of primary & secondary winding at 75° C per phase :- a CT Winding (i) Primary To be indicated

(ii) Secondary To be indicated b PT Winding (i) Primary To be indicated

(ii) Secondary To be indicated 11 Maximum attainable winding temperature 85° C

12 a Minimum phase to phase distance 255mm b Shortest distance between metal part

& earth 190 mm

13 a Make & type of HT bushing

To be indicated

b Creepage distance of HV bushing 300mm (Min)



14 Bi-metallic terminal connector with nut, plain washer, spring washer & check nut suitable for DOG ACSR Conductor (Dia 14 mm Approx.)

6 nos to be provided

15 Type of core material To be indicated 16 Size & capacity of conservator tank To be indicated 17 Type & thickness of gasket used on a Top cover tank To be indicated

b Secondary terminal box To be indicated c HV bushings To be indicated

18 Type & thickness of explosion vent diaphragm 19 Details of Metering Unit A CT details

a Cross section area of each turn of CT winding (in sq. mm.)

i. Primary winding To be indicated

ii. Secondary winding To be indicated b. No. of turns

i. Primary winding To be indicated ii. Secondary winding To be indicated c. Winding material

i. Primary winding To be indicated ii. Secondary winding To be indicated

B PT details a Cross Section area of each turn of PT (in sq. mm.)

i. Primary winding To be indicated ii Secondary winding To be indicated b Number of turns

i. Primary winding To be indicated ii Secondary winding To be indicated c Winding materials

i. Primary winding To be indicated ii Secondary winding To be indicated

20 Method of identification of i. Primary terminals ii Secondary terminals a CTs b PTs

21 Size and material of i. Primary studs jj Secondary studs

22 Method of jumper connection of (Bidders to indicate) i. Primary winding of CT/PT with

primary terminals

ii Secondary windings of CT/PT with secondary terminals



16.0 TECHNICAL SPECIFICATION OF HT TRI VECTOR METER 16.1. SCOPE:

This specification covers design, manufacturing, testing and supply of high precision three phase four wire static tri-vector energy meters of accuracy class 0.5S or better, capable of performing functions of tariff meters for energy audit in sub-transmission system & load survey applications. 1. STANDARD APPLICABLE : The meters shall be of class 0.5S accuracy and shall meet all the requirements specified in standard specifications IS:14697/1999, IEC:62053-22 and CBIP report no.88, with its latest amendment. 2. CLIMATIC CONDITIONS : The meter shall be suitable for operating under the following climatic conditions and shall be capable of maintaining desired accuracy under duly hot tropical climates.

a Maximum ambient air temperature 55oC B Maximum ambient air temperature in shade 45oC C Maximum temperature attainable by the meter exposed to sun 60oC D Minimum ambient temperature (-) 5oC E Average daily ambient air temperature 40oC F Maximum relative humidity 95% G Number of months of tropical monsoon condition 4 months h Maximum altitude above mean sea level 1000 meters I Average annual rain fall 150 cms J Maximum wind pressure 200 kg/sq.m K Isoceraunic level (days per year) 40 L Seismic level (horizontal accn.) 0.30 g m Permitted noise level 45.db

3. TECHNICAL REQUIREMENT & DESIGN CRITERION 4.1 Meters are required for installation in the premises of HT consumers or in sub-stations. The

basic system parameters for which these meters will be used shall be as under:-

Primary voltage 11KV/√3 (phase to neutral) Secondary voltage 110/√3 volts (phase to neutral) Primary current 11KV – 100Amp. Secondary current 5 Amps

Meters shall be designed on 3 phase 4 wire measurement principle & should have 3 current &

3 voltages measuring circuit i.e. one for each phase. 4.2 The meters shall work satisfactorily in the absence of neutral and shall work even if any two

voltage wires are extended to the meter. 4.3 The meters shall be designed for 5Amps CT Secondary and 200% overloading. 4.4 Accuracy - 0.5S 4.5 The meters shall have Non Volatile Memory (NVM) for storage of Billing and Tamper data.

There shall be no battery back up for retaining data. 4.6 Computation of demand shall be on the basis of Real Time Clock of the meter itself. 4.7 Meters covered under this specification shall be fully static type with non volatile memory to

register various billing parameters and complete with other features as detailed in this specification. Any other design meeting technical specification requirements or features/accuracy etc., better than this specification and as per relevant IEC/IS shall also be acceptable.



4.8 Meters shall be suitable for measurement of energy and other billing parameters within the specified limits of errors under balanced and unbalanced loads conditions in a poly phase network.

4.9 POWER FACTOR RANGE:- Meters shall be suitable for measurement of billing parameters

with specified accuracy for PF range Zero (lag) – unity – Zero (lead) 4.10 Computation of apparent energy shall be based on following principle. S = Sa + Sb + Sc Sa2=Pa2 + Qa2 Sb2=Pb2 + Qb2 Sc2=Pc2 + Qc2 S stands for Total apparent power Sa, Sb & Sc stands for apparent power in phase A, B & C P stands for Active energy Q stands for Reactive energy 4.11 KVAh computation shall be on the basis of power factor lag+lead Principle / lag only principle.

It should also be possible to change from (lag+Lead) to lag principle with the help of MRI & BCS.

4.12 Dial multiplying factor for the specified CTs & PTs ratio shall be unity. 4.13 The display of energy & also demand shall have minimum seven digits with fixed decimal. The

energy & demand shall be displayed in KWH & KVA or MWH & MVA respectively depending on CT and PT ratio.

4.14 The meter shall be programmable by the user for TOD timings, billing dates etc. 4.15 The meter constants shall be freeze and it shall not be possible by the manufacturer or the

user to alter the meter constants at factory or at site. 4.16 Provision shall be made to read various billing parameters and also load survey data through a

Common Meter Reading instrument. This arrangement can be through an optical coupler or any other suitable device galvanically isolated from meter circuit. Provision shall be made to seal the optical coupler to ensure proper security.

4.17 Indications shall be provided on display to show the healthiness of phase voltage and also the

status of abnormal electrical connections, if any persist at the meter terminals. 4.18 Meters shall be designed for satisfactory operation with the following supply voltage/frequency

variation:- Voltage - V.Ref + 15% to -30% as per standards Frequency - 47.5 Hz to 52.5 Hz (ref. frequency 50 Hz) For above voltage and frequency range, the meters shall measure, register and display various

parameters as per standards. 4.19 DISPLAY PARAMETERS 4.19.1 The data shall be displayed on LCD display (backlit type), which shall be clearly visible from

distance in 7 segment- 6 digits having minimum character height of 10 mm and additionally minimum 3 digits after decimal. It should be possible to easily identify the displayed parameters through symbols / legend on the meter display itself.

4.19.2 The display of the following parameters shall be continuously scrolling one after another through push button. The display shall have ‘ON’ time of at least 10 seconds of each measured value. Display parameters shall move forward if button pressed prior to the programmed time for display of each parameter.

4.19.3 The display Parameters and their Sequence should be as mentioned below:-

a) On pressing of Read push button i.e. billing parameters

i LCD segment check ii Date DD: MM: YY



iii Time HH:MM:SS iv Cumulative active energy import KWh/MWh v Cumulative active energy export KWh/MWh vi Cumulative apparent energy during KWh import KVAh/MVAh vii Cumulative apparent energy during KWh export KVAh/MVAh viii Maximum demand during the month Import mode KVA/MVA ix Maximum demand during the month Export mode KVA/MVA x Cumulative Maximum demand during Import & Export mode

separately KVA/MVA

xi MD reset counter No. of reset xii Tamper Information

b) Programmable Optional Requirements of display on pressing push button.

i.) Phase Current - A ii.) Phase Voltage - KV iii.) Instantaneous active Power - KW/MW iv.) Instantaneous reactive Power - KVAr/MVAr v.) Instantaneous demand - KVA/MVA vi.) Instantaneous PF - vii.) Frequency - Hz viii.) Reactive energy import while KWH import ix.) Reactive energy export while KWH import x.) Reactive energy import while KWH export xi.) Reactive energy export while KWH export xii.) Active TOD energy registers xiii.) Apparent TOD energy registers xiv.) TOD MD xv.) KVA (RISING DEMAND) Import/Export

xvi.) Billing TOD MD xvii.) Billing main active energy xviii.) Billing active TOD energy xix.) Billing main apparent energy xx.) Billing apparent TOD energy

c) Auto display:

i.) Date DD:MM:YY ii.) Time HH:MM:SS iii.) KWH cumulative Import/Export iv.) KVAH cumulative Import/Export v.) KVA Maximum demand during the month Import/ Export vi.) Instantaneous power factor vii.) Active TOD energy registers viii.) Apparent TOD energy register ix.) TOD MD x.) Billing TOD MD xi.) Billing main active energy xii.) Billing active TOD energy xiii.) Billing main apparent energy xiv.) Billing apparent TOD energy

4.19.4 VIEW PARAMETERS (display/information required through MRI/BCS)

i.) Reactive energy import while KWh import ii.) Reactive energy export while KWh import. iii.) Reactive energy import while KWh export iv.) Reactive energy export while KWh export v.) Present demand - KVA/MVA vi.) Power Factor vii.) Maximum demand during the month KW/MW Import & Export viii.) Tamper information. ix.) All balance parameters of (a) & (b) above.

Meter Reading at Power Outage:

Provision to read the meter in no power condition shall be made. The same push button shall be used for display the readings during power outage. A suitable internal/ external device could be used so that display of readings could be possible at least twice considering that



continuous power outage will not be for a period of exceeding 24 Hrs. Reading through MRI shall also be possible in power outage condition.

4.20 MAXIMUM DEMAND REGISTRATION 4.20.1 Maximum demand computation shall be based on sliding window concept/ block interval

concept (user selectable) with integration period of 30 minutes or 15 minutes programmable. For sliding window MD, there shall be three updates of 10 minutes or 5 minutes for 30 minutes or 15 minutes integration period respectively. By default computation shall be based on sliding window concept and integration period should be 15 minutes with 5 minutes update.

4.20.2 The MD integration cycle shall be on the basis of real time. However the real time clock of the

meter shall be used only for the purpose of time matching. For computation of maximum demand the internal clock of the meter shall be made use of.

4.20.3 Provision should also be made for automatic reset of MD at pre-defined period. The billing

parameter at the time of automatic reset of the MD along with one previous record shall be stored and display shall be possible on demand. Period as to when automatic reset of maximum demand is required shall be programmable. In addition reset of maximum demand shall be possible through a hand held terminal capable of communicating with the meter. In every case the design shall include provision of updating of cumulative demand register with updating of reset counter.

4.21 TAMPER DETECTION FEATURES :

a) Missing Potential - to indicate loss of potential in any or two phases of potential supply. The identification of phase, date and time of first occurrences, date and time of last tamper restore and cumulative number of tampering shall be indicated.

b) Reversal of CT - to indicate identification of phase, number of cumulative tampers (any one or

two phase’s reversal).

c) Current unbalance - to indicate number of hours there has been unbalance of current beyond the prescribed limits.

d) External magnetic influence – In the event of logging of presence of abnormal magnetic

induction with date and time the positive variation of error may be beyond the prescribed limit as prescribed in relevant standard/CBIP-88 report with latest amendments.

Along with the information, the meter shall also record the instantaneous values of all three-

phase voltages; three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events. The meter shall record 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. The event recording shall be compartment-wise roll over type i.e. it shall always maintain record of last 200 events occurred. Logics for design of above indicated tamper, the value of voltage, current, time etc. to be selected for design of tamper logics shall be in consultation with the purchaser. The tamper at (a) above is to be included in the DISPLAY PARAMETERS and information regarding rest of the tampers/unbalance etc. are required to be included as in information in the VIEW PARAMETERS.

e) Over current - to indicate number of hours there has been over current beyond the CT ratio limits.

f) Power Fail - The meter should log power down and power up event.

g) Security - The meter shall have the following unique security feature for different levels

described below.

Password Security level Operation 1 READ ONLY OPERATIONS

Read only such as Readings, Load Survey Event Reading.



2 LOW LEVEL RIGHT Set time, MD reset, Tamper reset

3 HIGH LEVEL RIGHT Tariff definitions, change bill dates, Persistence time change, MD reset options, Load survey configuration, changes in energy definition. Change of passwords for level 1, 2 and 3.

1. Passwords shall be zero for all 3 levels initially. With zero passwords the operations will

be available without getting password clearance. This will allow the user to choose whether to use passwords to prevent readings in particular, or to use only the authenticators to validate any data change transactions at levels 2 and 3.

2. Give tamper/fraud evidence where it is not possible to be tamper / fraud proof. This means

that meter has to record all authenticated transactions performed with it and communicate the recorded data in meter readings. Recording may include lock/unlock, password change, and transactions like change of energy definition, billing date programming, change of tariff for TOD tariff, tamper reset, load survey configuration, MD IP change etc. operation which involve change in meter configuration given in BCS scheduling with date and time.

4.22 Provision shall be made for push button to initiate display parameter in the front of the meter. 4.23 Provision shall be made for MD reset push Button with provision to seal it. 4.24 An operation indicator in the form of blinking optical Signal shall be provided to indicate that

the meter is operating satisfactorily. Supplier has to ensure the blinking optical signal is of weighted pulse and this can be effectively used for verification of accuracy & should also be ensured that the intensity of blinking signal is sufficient for detection by the optical sensor.

4.25 Meter shall be programmed for auto display of billing parameters with provision of:- - Programmable time display of each billing parameters. - Programmable time of display cycle. 4.26 Tamper information shall be roll over type and shall be FIFO based with facility to reset the

same through MRI. 4.27 TOD Tariff/Demand: The meter shall be capable of registering time of day energy consumption data on stand-alone

basis. The meter shall be provided with an internal time clock and timer both controlled by a quartz crystal with a battery totally independent of power supply and shall be capable of being set into a minimum of 6 time zones in a 24 hour cycle to cover morning and evening peak and off peak periods separately. Sufficient registers shall be provided to record and display the "display parameters” (Billing parameters) i.e. export & import active and apparent energy and demands for each time zone. The accuracy of the built in calendar and clock shall be better than one minute per month.

It should be possible to change the time period for these registers through the hand held

meter-reading device with special authenticated command from the BCS so that only authorized person(s) can make such changes. The main control for this change along with proper security password/code should be available on the computer located at the metering office. (The meter should be able to record energy consumption up to the specified time of day {as programmed} to help conducting regular energy balance study).

4.28 Load Survey Capability: It should be possible to store previous data of at least 31 days x 4 Parameters for interval of 15

minutes or 62 days x 4 parameters for interval of 30 minutes or 62 days x 2 parameters for interval of 15 minutes etc. (depending upon integration period and number of parameters) of energy consumed and also demand i.e. load survey is needed for the demand and energy consumed in every MD integration time cycle (15 min. or 30 min.). The demand to be recorded in the load survey shall match with the demand recorded in the "DISPLAY PARAMETERS". The demand and energy consumed shall be recorded separately under energy Import and energy Export periods. Load survey based on MD integration period shall be selectable from the following parameters.

-KWH Import



-KWH Export -KVAH Import (KVA While active import) -KVAH Export (KVA While active import) -RKVAH Import While KWH Import(KVAr lag with Active import) -RKVAH Export While KWH Import(KVAr lead with Active import) -RKVAH Import while KWH Export (KVAr lag while Active export) -RKVAH Export while KWH Export(KVAr lead while Active export) It should be possible to retrieve load survey data by hand held meter reading device through the

communication port provided on the energy meter. Out of the above-indicated parameters included in the load survey capability it shall be possible to select up to four parameters for load survey data. To clarify, the load survey memory shall be capable of accommodating and storing every 15 minutes data of at least four parameters. The choice of selecting any four parameters out of the parameters indicated above shall be user's selectable. By default the meters shall be programmed and supplied with following parameters:-

-KVA Import -KVA Export

-RKVAH Import While KWH Import (KVAr lag with Active import) -RKVAH Export While KWH Import (KVAr lead with Active import) 4.29 BILLING POINT REQUIREMENTS:

The predefined date and time for registering the billing parameters of active ,reactive, apparent energies of import and export along with its supported TOD registers and MD/ TOD MD as well as Tamper Count and Power-On hours readings shall be at 00.00 hours of the first day of each calendar (billing) month or any predefined date of the month. All billing parameters shall be transferred to billing registers

The above billing data, TOD register's data, load survey data, tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details.

Further, apart from instantaneous parameters like voltage, current, PF, and readings of billing

parameters, energy registers, TOD registers etc., the following additional parameters should be made available at the BCS end: a) MD reset count. b) Billing Parameters for last 12 Histories.

4.30 It should be possible to down load view parameters and load survey data on to compatible

computer and obtain full details of demand and consumption in statement form and also in graphic form.

Meters shall be four Quadrant meter capable of recording active reactive and apparent energy

and also demand in four quadrants. Meter shall be capable to measure fundamental frequency energy and total energy.

Meters shall be designed to withstand EMI-EMC level in accordance with clauses as mentioned in IEC/IS Standards for Class 0.5S. It is obligatory on the part of bidder to confirm this requirement and also to submit a type test/test report confirming successful performance

4.31 Necessary software for various programmable features as discussed above in the meter and

also necessary software for the IBM compatible computer as described below to obtain various details as discussed above and additional if any shall be provided by the supplier. No separate cost will be borne by the purchaser on this account. The software shall include provision for load survey, graphic presentation and other reports generation in BCS from the data collected from the meter through meter reading instruments.

In the forthcoming paragraphs requirement of a D-port/RJ-11 for tele-metering purpose has been described. Meters covered under this tender will be employed for metering at our Sub-stations or in the premises of HT consumers for tariff applications. In the cases the instantaneous parameters, load survey data and tamper information etc. will be monitored remotely through computer installed in central station. The data from meter will be transferred



to the central station through GSM/GPRS communication links as such meter should have capability of remote meter reading. It will be obligatory on the part of the bidders to supply the software in adequate copy needed for remote meter reading. No separate cost towards remote metering reading software will be born by the purchaser.

4.32 Lithium or any better quality battery of adequate storage energy shall be used for energy

supply to real time clock during no voltage or power off condition. 4.33 Under battery weak condition, an indication shall appear on MRI/Laptop/BCS. The life of the

lithium battery for supplying energy to real time clock during no voltage or power off condition should not be less than 10 years.

4.34 Output Device:- The meters shall have a test out put in the form of a blinking LED for testing

of the meters accuracy. Testing shall also be possible through optical port accessible from the front and can be monitored with Meter Reading Instrument having high-resolution display.

The meters shall give high-resolution energy values directly to meter reading instrument. The

resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. Meters shall have two numbers RS-232 communication port out of which one shall be galvanically isolated type and other D/RJ11 type for collection of data through the meter reading instrument and remote meter reading purpose. While designing these ports, due care shall be taken and it shall be ensured that damage to the meter/meter’s circuitry is not possible by injecting magnetic/electrical charges through these ports. A specific confirmation that these considerations have been taken care of shall be made by the bidder.

The port for load survey data collection shall be suitable to receive the coupler of MRI and certain

changes in the meter configuration as discussed else where in the tender should be possible through this and only this port. The other D-port/RJ-11 is exclusively for remote meter reading purpose only. Communication with meter through this port (D/RJ-11) for programming purpose should not be possible. Provision for sealing shall be made for both communication ports. For the output ports available in the meter standard internationally approved protocol shall be adopted. A detail of protocol used is necessarily required to be intimated by the supplier to the purchasers. In case any proprietary protocol/API is used, it will be obligatory on the part of the bidders to furnish complete details of proprietary protocol to the purchasers so that there may not be any difficulty in extraction of data from the meter through the available ports when connected to the communication bus (prepared for some other data communication purpose).

4.35 The meter should have provision for testing of meter in the meter testing laboratory or testing

of meter at site with the help of ESS and phantom load test set in order to reduce test time high resolution display on MRI should be provided.

4.36 Meter shall operate and record satisfactorily independent of phase sequence of input supply so

long as phase association between voltage and current circuits is in order. 4.37 The performance of meter should not be affected by the external electromagnetic interference

such as electrical discharge of cable and capacitor, harmonics, electrostatic discharge, external magnetic field and injection of D.C. Current in A.C. circuits etc.

4.38 The basic meter shall be designed for overloading up to 200% 4.39 No setting point / setting register etc. shall be provided for adjustment of measurement errors. 4.40 Midnight energy data:

Cumulative energies shall be logged at 00.00 Hrs. of every day and shall be maintained for last 35 day on FIFO basis. These energy snap shots shall be possible to view at BCS level. Daily energy snap shot for following energy shall be maintained:-

(i) Cumulative active energy KWH import/Export (ii) Reactive lag while active import (iii) Reactive lead while active import (iv) Cumulative apparent energy import/Export

4.41 BASE COMPUTER APPLICATION SOFTWARE

For efficient and speedy recovery of data read through CMRI/HHU, Base computer software shall be supplied having the following specifications as below:



The BCS software shall be user friendly. Windows based Base computer software shall be supplied. Base Computer software shall give all details adequate for analysis and load surveys parameters. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. EDP department of purchaser can generate its own DBF (data base files) to download all the required information into it.

i. Platform : The BCS shall be executable on all WINDOWS system. The BCS shall be suitable

to run on IBM compatible PC hardware platform.

ii. Meter Data Display :The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram)

All the information about energy, maximum demand and their respective TOD register reading,

billing register readings shall be shown in a manner which user can easily understand. All the load survey data shall be available in numerical as well as graphical format. It shall be

possible to view this data daily, weekly, and monthly format. The load survey graph will show values where the cursor is placed for the selected or for all parameter.

All the information about abnormality events shall be accompanied with date and time stamping along with 'snap-shot' of respective electrical conditions. This information shall be displayed in the sequence in which it happened in cumulative format as well as summary format.

The software shall be capable of preparing CMRI to read the meter information or time setting of the meter.

iii. Support Display: There shall be "user friendly" approach for viewing meter data for the

reading collected now or for the reading collected in the past. All information about a particular consumer will be sorted out and available at one place so that locating any consumer 's past data is easy. It shall be possible to retrieve/locate data on the basis of either one of the following particulars:

a) Consumer's ID/Numbers. b) Meter Sr. No. c) Date of meter reading. d) Location.

iv. The Data Transfer :It shall be possible to transfer data to and fro from CMRI through serial

interface. v. Remote Meter Reading option: It should be possible to read remote end meter using dial up

network/ GSM infrastructure with configurable auto reading mode and manual mode. The auto dialing and reading mode shall have enough flexibility to define different groups and their priority orders to read the meter etc.

vi. Configurability :It shall be possible to have selective printing of all available data of the meter.

Print out shall not include anything and everything available with the BCS. The software shall support "print wizard" whereby user can decide what to print out. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires.

BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. Here again an "Export wizard" or similar utility shall be available whereby user can select file format, what data to export, the field width selection etc.

vii. Security: The BCS shall have multilevel password for data protection and security. The first

level shall allow the user to enter the system. The different software features shall be protecting by different passwords. The configurable of passwords shall be user definable. The software installed on one PC shall not be copiable on another PC.

viii. Help: The exhaustive online help shall be available with the software so that user can use

all the features of the software by just reading the help contents. 4.42 APPLICATION PROGRAMME INTERFACE (API)



The bidder shall provide Application Programme Interface (API) to read their meters and convert the meter data as per IEEMA MIOS standard. Supply of API with the meter is mandatory.

4. CONSTRUCTION OF THE METER 5.1 Body of the meter shall be designed suitable for projection mounting. The meter should be

made of high quality raw materials to ensure higher reliability and longer life. The meter should be compact and reliable in design e.g. to transport and immune to vibration and shocks involved in transportation/handling. The construction of the meter shall be suitable for its purpose in all respects and give stable and consistent performance under all conditions especially during dust storms/heavy rains/very hot days.

5.2 All insulating material used in the construction of the meter shall be non-hygroscopic non

ageing and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion.

5.3 Meters shall be installed in Sub-stations/lines/HT consumer's premises out door inside a metal

box, directly under the sun and extreme weather conditions. Suitability of such a use shall also be confirmed.

5.4 SEALING OF THE METER:

Proper sealing arrangement shall be provided on the meter to make it tamper proof and avoid mishandling by unauthorised person. At least two (2) seals on the body, 2 nos. tamper evident sticker seals between the base and cover of the meter body, two (2) seals on the terminal block cover and one seal each on maximum device and communication port shall be provided. Beside body seal provided by the manufacturer, provision shall also be made to provide utility lash wire seals on the body. All the seals should be provided on front side only. Rear side sealing arrangement will not be preferred. The meter body one sealing screw shall be provided with good quality 7 digits numbered polycarbonate seal or any superior body sealing arrangement with embossing on sides, one side with the logo of firm and other side “MPEZ” The nos. of the seal shall be unique and should not be repeated in any case. Access to the working part should not be possible without breaking the seals. The polycarbonate seals shall have proper locking to avoid opening of the seal in any case by means of tampering. Meter body cover and base shall be solidly welded (seamless) such that it should not be opened without breaking the meter body.

TRACKING SOFTWARE FOR SEALS:

It is mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing, procurement, storage, record keeping, installation, series of inspections, removal and disposal etc.

5.5 TERMINAL BLOCK COVER:

The terminal block cover for the meter shall be extended transparent type, which can be sealed independently & over the meter cover. The terminal cover shall enclose the actual terminals, the conductor fixing screws and 10mm of the external conductors and their insulation for which the terminal cover shall be of extended type. The terminals shall not be accessible without removing the seals of the terminal cover when energy meter is mounted on the meter board.

5.6 CONNECTION DIAGRAM & TERMINAL MARKING:- The connection diagram of the meter shall be clearly shown on inside portion of terminal cover

and should not fade with time. Meter terminals shall also be marked and should appear in the above diagram.

Meter shall have a name plate clearly visible, secured against removal & indelibly and distinctly marked with all the essential particulars as per relevant standards i.e.

a. Manufacturer’s name and trademark b. Serial number c. Type and description d. Rated current, voltage and frequency e. Relevant ISS/IEC No. along with ISI certificate mark, wherever available. f. Meter constant shall invariably be indicated. g. Name of the owner, purchase order no. & date and month/year of manufacturing shall

be printed.



h. Guarantee Period

5.7 ISI CERTIFICATION MARK: The meters must bear “ISI” certification mark

5. TEST 6.1 TYPE TEST:- The type test certificate for all tests as indicated in relevant standards (with

latest amendments) or CBIP report No.88 shall be furnished along with the bid. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. Type test report, amongst other details, should contain the following information clearly: Type of meter Class of Accuracy.

Type test certificate from educational institute(s) will not be accepted. The type test certificate shall not be more than 24 months old as on the date of opening of bid.

6.2 ACCEPTANCE TEST:- All acceptance test as per IS:14697/1999, IEC:62053-22 & CBIP report

No.88 shall be carried out on the meter.

6.3 ROUTINE TEST:- All routine tests as per IS-14697, IEC:62053-22 & CBIP report No.88 shall be carried out on all the meters.

6. PRE DESPATCH INSPECTION: All acceptance tests and inspection of meter/software shall be carried out at the place of manufacturer unless otherwise specially agreed upon by the manufacturer and purchaser. The manufacturer shall offer to the inspector representing the purchaser all the reasonable facilities, free of charge for inspection and testing to satisfy him that the material is being supplied in accordance with this specification. The Discom’s representative/Engineer attending the above testing will carry out testing as per, IS:14697 /IEC:62053-22 & CBIP report No.88 and this specification. 7. GUARANTEE The Defect liability period shall be as mentioned in clause GCC 27.10 of SCC in Section 8 of the Bid document. 8. MINIMUM TESTING FACILITIES:

Manufacturer should posses fully computerized Meter Test Bench for carrying out routine and acceptance tests as per relevant ISS. In addition this facility should produce Test Reports for each and every Meter. The bidder should have the necessary minimum testing facilities for carrying out the following tests.

i) A.C. Voltage test ii) Insulation Resistance Test iii) Test on limits of errors iv) Test on meter constant v) Test of starting condition vi) Test of no load condition vii) Repeatability of error test viii) Test of power consumption ix) Vibration test x) Tamper conditions - as per MPEZ Specification

The manufacturer should have duly calibrated ESS meter of class 0.1 or higher accuracy.

9. QUALITY ASSURANCE PLAN:

The designed life of the meter shall be minimum 20 years and to prove the designed life, the firm shall have at least the following Quality Assurance Plan:-

a. The factory shall be completely dust proof. b. The testing rooms shall be temperature and humidity controlled as per relevant

standards. c. The testing and calibrating equipments should be automatic and all test equipment

shall have their valid calibration certificates. d. Power supplies used in testing equipment shall be distortion free with sinusoidal,

wave- forms and maintaining constant voltage, current and frequency as per the relevant standards.

e. During the manufacturing of the meters the following checks shall be carried out. i. Meter frame dimensions.



ii. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated.

iii. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any possibility of human errors.

The Bidder shall invariably furnish the following information along with his bid, failing which his bid shall be liable for rejection. Information shall be separately given for individual type of material offered.

(i) Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list of standards according to which the raw materials are tested, list of tests normally carried out on raw material in presence of bidder’s representative and copies of test certificates.

(ii) Information and copies of test certificates as in (i) above in respect of bought out

accessories.

(iii) List of manufacturing facilities available.

(iv) Level of automation achieved and list of areas where manual processing exists.

(v) List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.

(vi) List of testing equipments available with the bidder for final testing of equipment specified

and test-plant limitations, if any, vis-à-vis type, special acceptance and routine tests specified in the relevant standards and this specification. These limitations shall be very clearly brought out.

(vii) The manufacturer’s laboratory must be well equipped for testing of the meters. They must

have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished with tender document.

10. MANUFACTURING ACTIVITIES:- (i) Meter should be manufactured using SMT components and by deploying automatic SMT pick

and place machine and reflow solder process. Further, the Bidder should own or have assured access (through hire, lease or sub-contract) of above facilities.

(ii) Quality control should be ensured at the following stages:

(a) At PCB manufacturing stage, each board shall be subjected to computerized bare board testing.

(b) At insertion stage, all components should undergo computerized testing for conforming to design parameters and orientation.

(c) Complete assembled and soldered PCB should undergo functional testing using Automatic Test Equipments (ATEs).

(d) Prior to final testing and calibration, all meters shall be subjected to aging test (i.e. meters will be kept in ovens for 72 hours at 55°C temperature and atmospheric humidity under real life condition at its full load current. After 72 hours meters should work satisfactorily to eliminate infant mortality.

(iii) The calibration of meters shall be done in house. 11. PACKING:-

Each meter should be shrink packed to avoid any scratches on meter body, dust from entering etc. and should be packed in a cushion cartoon of 10 meter or any appropriate quantity.

The packing cases should be marked to indicate the fragile nature of the contents. 12. DRAWING AND TECHNICAL LEAFLETS:- Individual meters should contain connection diagram on transparent terminal cover. All other details such as general arrangement, installation details operation instructions etc. should be given in the manual, which shall be supplied to the consignee. Two sets of such manuals shall be supplied to each consignee and two sets to this office.



13. GENERAL:- a) Principle of operation of the meter, outlining the methods and stages of computation of various

parameters starting from input voltage and current signals including the sampling rate, if applicable, shall be furnished by the bidder.

b) The bidder shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT/shunt, potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period.

c) The bidder shall furnish details of memory used in the meter.



17.0 TECHNICAL SPECIFICATION OF INTELLIGENT GSM MODEM

1. The overall system setup shall consist of the following:

Meter end (consumer premises) –

• GSM modem (GPRS enabled) with high gain antenna • Suitable communication cable between modem and meter • External Antenna with cable Central Station end –

• Transparent GSM modem (GPRS enabled) with communication cable and External Antenna

• Base Computer Software

The modem shall be suitable for communication with electronic energy meters to be installed at various feeders. The system shall be used for remote meter reading of the consumer meters via GSM infrastructure. The communication and reading shall be enabled with suitable Base Computer Software (BCS). The modem shall offer in-built intelligence and high speed data transfer rate or a kind of store–forward facility by which all instantaneous and stored data of the meter is read at regular intervals and stored in modem’s internal memory and forward to remote central station (as configured) for viewing billing and reporting via Base Computer Software. The modem provided with Store and forward facility shall also be capable to transfer the meter data directly from meter to the PC. Various features of GSM modem (to be installed with electronic energy meter) are described

as below:

2.1 Power Supply Section 2.1.1 Input supply

a. The modem shall have an AC input supply of 110V/230V + 30%, 50 Hz. b. The modem should be capable of proper functioning within the power supply range of 77

to 299V AC. c. Average Power consumption of the modem shall be 3 VA approx under idle condition and

6 VA approx during data transfer.

Note: Power consumption may vary from site to site depending on signal strength at that particular location. Above values are typical values.

2.1.2 Withstand capacity against surges should be according to Indian conditions i.e. 6.0 kV. 2.1.3 Input terminals: The power supply input shall be through a suitable two core integrated cable

coming out from modem box. 2.1.4 The modem shall have capability to work under continuous power on condition.

2.2 GSM Section

The GSM module shall comply with the following:

2.2.1 The modem shall operate in GSM 900/1800/1900 MHz Band. 2.2.2 The modem shall be compliant with ETSI GSM Phase 2+ Standard.

Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800/1900 MHz

2.2.3 The modem shall support Point-to-Point transmission and Cell Broadcast features.

2.2.4 It shall have auto dial feature.

SIM Card Section For placing the SIM Card, a SIM Card Holder shall be provided on the GSM motherboard and shall be

accessible only by removing the cover of the GSM modem. The SIM Card shall be of 3V Interface. Interlocking facility shall be provided under the device cover.

Communication Interface A RS232 Serial Link supporting up to 9600 bauds with an auto-bauding option shall be provided.

However the data transfer rate for remote meter reading shall depend on meter compatibility. The RS232 output shall be provided on a 9-pin female connector which can be connected to electronic

energy meter’s optical / serial communication port through suitable communication cable.



RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band Antenna can be connected. The antenna should be of minimum 3dbi gain. Provision shall also be made to connect 14db high gain external yagi antenna to improve poor signal strength.

Network Identification Section

For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data).

3. EMI/EMC Specifications

The GSM modem shall meet the following EMI/EMC specifications:

a. Electrostatic Discharge IEC61000-4-2 b. Fast Transient Burst IEC61000-4-4 c. Surges Immunity IEC61000-4-5 (Under Line to Earth & Line to Line immunity) d. Conducted Emission CISPR22 (class B)

4. Mechanical Specifications

The Mechanical Specifications of the modem shall be as follows: a. Mounting Arrangement: A suitable wall mounting arrangement shall be provided. b. The GSM modem shall comply with IP50 rating. c. Sealing Arrangement: The Top and Base Cover shall have a suitable sealing

arrangement so that the GSM SIM Card cannot be tampered with. d. The modem shall be housed in an enclosure of ABS Plastic.

5. Environmental specifications

The modem shall meet the following environmental specifications: Temperature: -10 degrees to +55 degree Humidity: 95% RH (non – condensing)

6. Functional specifications

The modem should be an intelligent device and capable of providing the following functionalities:

6.1 Inbound dialing (a) The modem should have inbound dialing facility i.e. modem shall automatically dial to a

particular GSM number (number of modem placed at central station end along with BCS server) at specified time (once in a day/week/month) for the purpose of meter reading. This configuration of the modem shall be made available to the user via offered Base Computer Software.

(b) If modem at consumer end could not establish connection to the modem at central station at specified time, then it shall retry the same as configured.

6.2 Outbound Dialing

(a) In case the data is required by dialing from the Central station end (Server end), then connection shall be established by the server to the device using AT commands and transparent communication mode shall be established.

(b) User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem.

6.3 Event based dialing (a) Other than regular dialing, the modem shall have feature of event based dialing in

case of logging of tamper by the meter, without waiting for the interrogation from central station (BCS server) and meter data shall be sent to the central station

(b) Further, the modem shall send an SMS to predefined mobile number and the SMS shall contain meter serial no. The mobile number shall be configurable via BCS.

(c) Event based dialing and SMS shall be applicable for the event types (tamper/anomaly) as supported/recorded by the meter

(d) When the modem is busy in collecting the data from the meter and the call comes to get the data, then priority shall be given to outbound call rather than data collection from meter.

(e) The feature of event based dialing shall be user configurable. Provision of enabling and disabling of the feature shall be provided



VERIFICATION/TESTING OF MATERIAL SUPPLIED

a) Type test In case of order, three (3) samples for Type Test shall be selected & sealed by authorized person of MPPKVVCL from the first lot received in Company’s Area stores. The selected samples shall be sent with complete details for type test at CPRI / ERDA / any NABL accredited test house. The type test charges shall be borne by the supplier. In case of successful type test results, supplies shall be continued. However, in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s), three more samples shall be selected from the supplies already received to get them type tested at supplier’s cost. In case of repeat failure in type test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. b) Acceptance test i) On receipt of subsequent consignment of individual DI in Area Stores, set of meters as per relevant

standards shall be selected randomly and sent to CPRI/ERDA for conducting acceptance test as per the prescribed procedure.

ii) In case of failure of samples of lot/ sub-lot in the test(s) detailed in ISS, the similar testing

procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the supplier at his own cost. Repeated failure/poor results in the testing may render cancellation of order.

iii) The supplies, at the option of purchaser, may be utilized in the field during the period of testing. In

case of repeat failure in acceptance test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost.

iv) The purchaser also reserves the right to get additional samples for all or any of the selected tests at

purchaser's cost at any independent test house at any stage of supply, if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. In case of failure, the guarantee period of the quantity already supplied by the supplier shall be doubled and purchaser reserves the right to cancel the balance quantity.

c) In case of failure in type test or acceptance test, purchaser may allow the supplier to re-offer the

material after change/ modification in the design of meters. The balance material shall be accepted only after successful Testing. The Testing charges shall be borne by the supplier.



GUARANTEED TECHNICAL PARTICULAR FOR TRIVECTOR STATIC (ELECTRONIC) ENERGY METER

S.N. Particulars Minimum requirement Offered by the Firm

PART - A

1 Name of manufacturer

2 Type & make

3 Standard Applicable IS:14697/1999, IEC:62053-22, CBIP report 88 with latest

amendment

4 Model

5 Rating

(i) Accuracy class 0.5s

(ii) Rated voltage 110/ √3 (P-N)

(iii) Rated current Secondary 5 Amps

(iv) Rated frequency 50 Hz ± 5%

(v) Power factor range As per relevant ISS

(vi) Minimum saturation current > 200% of Ib

(vii) Shall work within accuracy up to max. loading(Imax)

200% of Ib

6 (i) Continuous current rating (Amp) 5 Amps as the case may be

(ii) Running with no load Voltage applied 115% of reference voltage

No creeping

7 Short time over current 20 times of Imax for 0.5 sec.

8 Starting current (Min) at which meter shall run & continue to run

0.1% of Ib

9 Power loss at rated frequency & reference temperature

(i) Current circuit at rated current per phase

As per ISS/ CBIP 88

(ii) Voltage circuit at rated current per phase

As per ISS / CBIP 88

(iii) Meter load on PTs As per IEC 62053-22/ CBIP 88

10 Momentary over voltage As per IEC 62053-22/ CBIP 88

11 Dielectric voltage withstand 6 KV AC

12 Communication port The meter shall be provided with two output ports, out of which

One optical port for load survey facility and another D-type or RJ-11 port for transfer of meter data

through modem/RTU.

•

13 Battery backup -Battery backup is not required for memory. Only for real time clock lithium battery backup is required during no voltage or power off condition. -Meter shall be provided with indication of weak battery condition.

14 Type of material used

(i) Base High impact strength flame retardant, UV stabilized polycarbonate/ Engineering plastic.

(ii) Terminal block - do -

(iii) Meter cover - do -



(iv) Terminal cover - do -

(v) Screw Nickel plated Brass

(v) Screw size M - 4 x 6 mm

15 Type of display 7 segment LCD

(i) No. of Digits display 6 digits 7 Segment LCD display (High resolution display for the energy shall be provided. In which minimum three digits after decimal shall be provided additionally)

(ii) Character size of display 10x5 mm or better

16 Fixing/ Sealing arrangement

(i) Fixing of meter 3 fixing holes (one at top and two at bottom terminal block)

(ii) Sealing of meter cover to Base As per clause 4.4 of the TS

(iii) Sealing of terminal cover Two

(iv) MD Button One

(v) communication port One

(vi) provision shall also be made on the

body To provide utility lash wire seals

17 Performance of meter in tamper condition

Should work within specified accuracy as per electrical

conditions

18 Reverse phase sequence Meter shall record energy accurately.

19 Size of calibration LED and color 5/3mm Red

20 Electromagnetic compatibility EMI/EMC severity level)

Should withstand severity level 4 or as per CBIP:88 latest

amendment

21 Effect on accuracy of external electromagnetic interference of electrical discharge, external magnetic field & DC current in AC supply or in neutral, capacitor switching and harmonics etc.

Should work within accuracy as per CBIP 88/ IEC:62053-22

22 Effect of accuracy in tamper condition Should work within specified accuracy as per standards

23 Cut off voltage (at which meter stop working)

Please specify

24 Input voltage & frequency variation within which meter works satisfactory

+ 15% to -30% of Vref ±5% of reference frequency

25 Relative humidity 95% (some times approaches to saturation)

26 Rf. temperature 27°C

27 Temperature range of operation -5 to 55°C

28 Drift in accuracy of measurement with time

No Drift in accuracy in measurement with time

29 Fixing arrangement of name plate Secured and indelibly marked name plate (rating plate) will be fixed to the meter under display

window.

30 Approximate weight of meter To be mentioned

31 Type of body Projection type

PART - B 1. Manufacturing activity i) Whether SMT components &

technology used SMT component & technology necessary

ii) Whether submitted quality assurance Required to submit



plan 2. Testing facility i) Whether fully automatic computerized

meter test bench with print out facility available

Must available

ii) Make & S.No. of Test bench - iii) Accuracy of RSS/ESS duly calibrated To be indicated iv) Whether following in-house testing

facility available:

a) Insulation resistance Must be available b) Running on no load -do- c) Starting current Must be available d) Accuracy requirement -do- e) Power consumption -do- f) Repeatability of error -do- g) Vibration test -do- h) Tamper condition -do- i ) Electromagnetic compatibility -do- 3. Whether offered meter type tested as per ISS 14697/199 9 Table-16 for all the following tests

(indicate name of laboratory/ Ref. of report No. & dt.)

Clause of ISS

Name of Lab

Type test report no.

Ref. page no. of offer

I) Test of Insulation properties 12.7.6

i) Impulse voltage test 12.7.6.2 ii) AC high voltage test 12.7.6.3 iii) Insulation test 12.7.6.4 II) Test of Accuracy Requirement

i) Test on limits of error 11.1 ii) Interpretation of test results 12.15 iii) Test of meter constant 12.14 iv) Test of starting condition 12.13 v) Test of no load condition 12.12 vi) Test of ambient temperature influence 12.11 vii) Test of repeatability of error 12.16

viii) Test of influence quantity 12.10 III) Test of Electrical Requirement 12.7

i) Test for power consumption 12.7.1 ii) Test of influence of supply voltage 12.7.2 iii) Test of influence short time over current 12.7.3 iv) a) Test of influence of self- heating 12.7.4 b)Test of influence of heating 12.7.5 IV) Test for Electromagnetic compatibility 12.8

i) Radio interference measurement 12.8.5 ii) Fast transient burst test 12.8.4 iii) Test of immunity to electrostatic discharges 12.8.2 iv) Test of immunity to electromagnetic HF

field 12.8.2

V) Test for climatic influence 12.6

i) Dry heat test 12.6.1 ii) Cold test 12.6.2 iii) Damp heat cyclic test 12.6.3

VI) Test for mechanical Requirement 12.3

i) Vibration test 12.3.2 ii) Shock test 12.3.1 iii) Spring hammer test 12.3.3 iv) Protection against penetration of dust and

water 12.5

v) Test of resistance to heat and fire 12.4



4. Guaranteed life of meter 10 years minimum 5. BIS license No. & dt. with its validity for ISI

certification mark on different meter (If available)

To be mentioned

6. ISO license No. & dt. with its validity To be mentioned 7. Past experience i) Order received up to date of submission

of offer Ord.No.& dt. Qty.

Name of SEB/

Power Utility. a) 110 Volt static trivector meters ii) Qty. supplied up to date of submission of

offer (Note - copy of order be enclosed specifically along with its technical specification)

To be indicated/ submitted

8. Other parameters/features not covered in the above GTP

Shall conform to specification of IS-14697/1999,IEC:687 & CBIP report No.88 (Revised version with its latest amendment

(1) Certified that all the information/parameters indicated above shall exist in the meter offered &

shall stood all the tests specified above within the variation of current/voltage frequency and climatic conditions specified therein.

(2) Even if any feature or parameter not specifically covered in this GTP, but essential as per the

detail specification, is deemed to be covered in the GTP.



18.0 Copper control cables: 18.1 SCOPE: Specification calls for design, manufacture, stage testing, inspection and testing before

dispatch, packing and delivery of Copper control cables and Aluminum power cables for 33/11 KV substations in the state of Madhya Pradesh.

The control and power cables shall be ISI marked, 1.1 KV Grade. The cores shall have a size

of 2.5 sq.mm for control cables and 4 sq. mm. power cable, using solid/starnded Copper conductor with different number of cores as specified below:-

18.1.1 COPPER CONTROL CABLES:

Unarmoured i) 12 Core 2.5 sq.mm, solid conductor i) 8 Core 2.5 sq.mm., solid conductor. ii) 4 Core 2.5 sq.mm., solid conductor iii) 2 Core 2.5 sq.mm., solid conductor

18.2.1 STANDARDS: The control and power cables shall conform to the latest applicable Indian Standards. In case bidders offer control and power cables conforming to any other International Standards which shall be equivalent or better than IS, the same is acceptable.

S. No.

Standard Ref. No.

Title

1 IS: 1554 PVC insulated (Heavy Duty) Control Cables for working voltage & including 1100 Volts.

2 IS: 3961 Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables

4 IS: 4905 Methods of random sampling 5 IS: 5831 PVC insulation and sheath of electric cables 6 IS: 8130 Conductors for insulated electric cables and flexible cords 7 IS: 10418 Wooden drums of electric cables 8 IS: 10810 Methods of tests for cables

18.2.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS

In above paragraph relevant Indian Standard have been mentioned. However, the cables meeting any other authoritative International Standard which ensures equal or better quality than the standards mentioned, shall also be acceptable. Cables for which Indian Standards are not available, the relevant equivalent International Standards will be applicable. Please attach photocopy of all such standards according to which the cables have been offered.

18.2.3 CLIMATIC CONDITIONS:

The Control and Power cables to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions :-

1 Location At various substations in the

State of Madhya Pradesh 2 Maximum ambient air temperature 50°C 3 Minimum ambient air temperature 1°C 4 Maximum Daily average ambient air temperature 40°C 5 Maximum Yearly Weighted average temperature 32°C 6 Maximum Relative Humidity 95% (Sometimes approaches

saturation) 7 Maximum altitude above mean sea level 1000 Metres 8 Average Annual Rainfall 125 cm 9 Maximum Wind Pressure 150 Kg/Sq. metre 10 Isoceraunic level (Average Number of thunderstorm days 50



1 Location At various substations in the State of Madhya Pradesh

per year) 11 Seismic Level (Horizontal acceleration) 0.3 g 18.3 SYSTEM PARTICULARS: Cables offered under this specification shall conform to the parameters given below :

S. No.

Particulars System Voltage

1 Frequency 50 Hz 2 Earthing Effectively Earthed

18.4 GENERAL TECHNICAL REQUIREMENTS AND CONSTRUCTIONAL DETAILS: Cables shall be suitable for laying on racks, in ducts, trenches, conduits and underground

buried installation with chances of flooding by water. Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady-state and transient operating conditions as specified elsewhere in this specification.

18.5 COPPER CONTROL CABLES: Control cables shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC

insulated, PVC inner sheathed, unarmoured, PVC outer sheathed with solid copper conductor conforming to latest version of IS: 1554 or equivalent International Standards.

18.6 CONDUCTOR:

The conductor shall be made from high conductivity copper rods complying with latest version of IS:613 or equivalent International Standards. The conductor shall consist of annealed copper wires complying with IS: 8130 with latest amendments or equivalent International Standards.

18.7 POWER CABLES:

Power cable shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, PVC outer sheathed with stranded stranded conductor.

18.8 INSULATION: Conductor shall be provided with PVC insulation applied by extrusion in accordance with latest

version of IS: 5831 or equivalent International Standards. The average thickness of insulation shall be in accordance with the IS: 1554 (Part-I) with latest amendments or equivalent International Standards.

Insulation shall be so applied that it fits closely on the conductor and shall be possible to remove it without damages to the conductor.

18.9 CODE IDENTIFICATION: Colouring of insulation shall identify cores of the cables of upto 5 cores. Following colour

schemes shall be adopted:-

SN Number of Cores Colour Scheme 1 1 Core Red, Black, Yellow or Blue 2 2 Cores Red and Black 3 3 Cores Red, Yellow and Blue 4 4 Cores Red, Yellow, Black and Blue 5 5 Cores Red, Yellow, Black, Blue and Grey 6 6 Cores and above Two adjacent cores (counting and direction core) in each layer, Blue

and Yellow, remaining cores Grey or in accordance with the scheme given in IS: 1554 Clause 10.3



For reduced neutral conductors, the insulation colour shall be Black. Cables having more than 5 cores, as an alternate to the provision of (6) above, core identification may be done by numbers as indicated in latest version of IS: 1554 (PART-I) 10 core identification.

18.10 LAYING UP OF CORES: In multi-core cables, the cores shall be laid up together with a suitable lay, the outer most layer

shall have right-hand lay and successive layer shall be laid with opposite lay, where necessary, the interstices shall be filled with non hygroscopic materials.

18.11 INNER SHEATH: The laid up cores shall be provided with inner sheath applied by extrusion. It shall be ensured

that the shape be as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. Thickness of inner sheath shall be conforming to latest version of IS: 1554 (Part-I) or equivalent International Standards.

18.12 FILLER AND INNER SHEATH: Filler and inner sheath shall be of the following:

• Unvulcanised rubber, or • Thermoplastic materials, or • Proofed tape (for inner sheath only)

Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. Material shall be chosen to be compatible with temperature ratings of the cable and shall have no deterious effect on any other component of the cable.

18.13 OUTER SHEATH: The outer sheath shall be applied by extrusion. It shall be applied:

• Over the inner sheath in case of unarmoured multicore cables. Outer sheath shall be so applied that it fits closely over insulation / inner sheath / armouring. It shall be possible to remove it without damage to the insulation / inner sheath. The colour of the outer sheath shall be black. Thickness of outer sheath insulation shall conform to latest version of IS: 1554 Part-I or equivalent international standards.

18.14 IDENTIFICATION:

In addition to manufacurer’s identification on cable as per clause-17.1 of IS: 1554 (Part-I) with latest amendments, following marking shall also be embossed over outer sheath at every three meters:-

• Cable size and voltage grade • Word “MPPKVVCL” and Name of manufacturer • ISI marking and sequential marking by means of embossing

The embossing shall be in line throughout the length of the cable and shall be legible and indelible.

18.15 PACKING AND MARKING: Cables shall be supplied in non-returnable drums. The surface of the drum and outer most

cable layer shall be covered with waterproof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC or rubber caps, secured by ‘U’ nails so as to



eliminate ingress of water during transportation storage and erection. Following information should be stenciled on the drum:

• Reference to relevant Indian or International Standard. • Manufacturer’s name, brand name or trade mark • Type of cable and voltage grade • Number of cores • Nominal cross-sectional area of the conductor • Cable code • Colour of cores • Length of cable on the drum • Number of lengths on drum (if more than one) • Direction of rotation of drum by means of an arrow • Approximate gross weight • Running end of cable • Country of manufacturer and year of manufacture

As mentioned, the cable drum must bear relevant Indian/International Standard certification Mark. In this connection, a certified photostat copy of valid standard marking license rights duly attested must be submitted along with the inspection offer as documentary evidence. In absence of these documents, the inspection offer will not be considered.

18.16 STANDARD DRUM LENGTH:

Standard drum length for cable shall be 500/250 metres.

18.17 TOLERANCE: Tolerance on the overall diameter of the Cable shall be ± 2 mm over the declared value in the techanical data sheets of Guaranteed Technical Particulars. Length per drum shall be subjected to maximum tolerance of ± 5% of the standard drum length. The Employer shall have option to reject cable drums with shorter length. Over all tolerance in total quantity for each type and size of cables shall be ± 2%.

19.18 TESTS: All types and sizes of cable being supplied shall be subjected to Type tests, Additional test, Routine tests and Acceptance tests as specified below at the expense of Agency and according to relevant standards.

18.18.1 TYPE TESTS AND ADDITIONAL TESTS: It is essential to furnish all the type test reports for each type and size of cable as stipulated in latest version of IS: 1554 (Part-I) and following Additional Tests:

• Loss of mass test • Heat shock test • Thermal stability test • Accelerated water absorption test • Dielectric strength retention test

Above tests shall be conducted in NABL approved Testing laboratories only. 18.18.2 ACCEPTANCE TEST

Acceptance test shall be caried out on each type and size of cables on cable drumsselected at random as per following plan :- S.No. Numbers of Drums in the Tests Number of Drums to be

taken as samples 1 Upto 50 2 2 Upto 51 to 100 5 3 From 101 to 300 13 4 From 301 to 500 20



5 Above 501 32

The following shall constitute acceptance tests :-

• Annealing Test • Conductor Resistance Test • Wraping Test • Tensile Test • Test for Thickness of Insulation and Sheath • Tensile Strength and elongation test before ageing and after ageing at break of insulation

and sheath • High Voltage Test (Water Immersion Test) • High Voltage Test at Room Temperature

18.18.3 ROUTINE TESTS:

Routine test shall be carried out for each drum of cables of all types and sizes. Following shall constitute routine tests : • Conductor Resistance Test • Resistance Test • High Voltage Test at Room Temperature

COPPER CONTROL CABLE

S.No. Particulars Provision made/Give details of make, rating etc.

1 Name of Manufacturer 2 Adress of Manufacturer 3 Standard applicable 4 Rated Voltage 5 Suitable for earthed or unearthed system 6 Permissible voltage & frequency variation for

satisfactory operation

A Voltage B Frequency 7 Continuous current rating when laid in air in an ambient

temp. 40ºC and for maximum conductor temperature 70ºC

8 Derating factor for the following A Variation in ambient temp. (for cables laid direct in air)

from Deg. C in steps of Deg. C

B Variation in ambient temp.(forcables laid direct in ground) from Deg. C in steps of Deg. C

9 Furnish chart showing derating factor for different spacing of cables considering multicore cables installed in horizontal formation in single row as well as in different tiers under the following methods of laying

A Cables laid in formed concrete cable trenches with removable covers

B Cables laid in cable trays C Cables laid in ground D Cables laid in pipes or ducts 10 Depth of laying for cables laid directly in the ground 11 Depth for variation in thermal resistivity of the soil 12 Current carrying capacity A Short Circuit Amps (rms) B Duration of short circuit C Conductor temperature allowed for Short Circuit 13 Loss tangent at normal Frequency 14 Dielectric constant at normal frequency 15 Conductor details A Material B Nominal cross section area



S.No. Particulars Provision made/Give details of make, rating etc.

C Number and diameter of Wires D Received from (Bidder/manufacturer’s name) 16 Insulation details A Composition B Thickness C Tolerance on thickness D Approximate diameter of Sheath E Specific insulation resistance at 60ºC F Received from (Bidder/manufacturer’s name) 17 Colour scheme for identification 18 Innder sheath details A Material B Extruded, please confirm C Calculated diameter over the stranded cores D Thickness E Tolerance on thickness F Received from (Bidder/manufacturer’s name) 19 Outer sheath details A Material B Extruded, please confirm C Calculated diameter under the sheath D Thickness E Tolerance on thickness F Received from (Bidder/manufacturer’s Name) 20 Armour A Type of Armour B Nominal diameter over the inner sheath C Nominal dimension of strip or diameter of round wires D Received from (Bidder/manufacturer’s name) 21 Overall diameter of cable over the outer sheath 22 Conductor resistance at 20ºC per Km. 23 Reactance at 50 Hz per Km. 24 Capacitance at 50 Hz Per Km. 25 Insulation resistance at 20ºC per Km or Volume

resistivity at 27ºC & 90ºC

26 Conductor temperature corresponding to maximum continuous current

27 Dearating factor using A Class Q cartridge B Class Q semi enclosed fuse 28 Test Voltage A High Voltage test B After immersion test voltage 29 Recommended minimum installation radius 30 Safe pulling force when pulled by pulling eye 31 Cable Drum A Dimensions of the Drum B Approximate Weight of Drum C Maximum length per drum for each size of the cable 32 Net weight of cable (Kg per Km)



19.0 DANGER BOARD:

As per provisions of IE Rules 1956, danger notice plates in Hindi with the signs of skull and bones is required to be provided on power line supports and other installations. This specification covers danger notice plates to be displayed in accordance with Rule No.35 of Indian Electricity Rules, 1956. Unless otherwise modified in this specification, the Danger Notice Plates shall comply with IS 2551-1982 or the latest version thereof. Dimension: Two sizes of Danger Notice Plates as follows are to be installed at each substation:

a) For display at 11 KV installations - 250 x 200mm

Corners of the plate shall be rounded off. All lettering shall be centrally spaced. The dimensions of the letters, figures and their respective position shall be as shown in figs. 1 to 4. The size of letters in the words in each language and spacing between them shall be so chosen that these are uniformly written in the space earmarked for them. Type and size of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3 of REC specification. Adequate space has been provided in the specimen danger notice plates for having the lettering in local language for the equivalent of ‘Danger’. ‘11000’ and ‘Volts’. The plate shall be made from mild steel sheet of at least 1.6mm thick or FRP based sheet moulding compound(SMC) of 2.00 mm thickness (SMC as per IS:13410) and vitreous enameled white, with letters, figures and the conventional skull and cross-bones in signal red color (refer IS:5-1978) on the front side. The rear side of the plate shall also be enameled.

TESTS: The following tests shall be carried out: i) Visual examination as per IS:2551-1982 ii) Dimensional check as per IS:2551-1982 iii) Test for weather proof-ness as per IS:8709-1977 (or its latest version).



20.0 GALVANISED MILD STEEL HEXAGONAL HEAD BOLTS AND NUTS 20.1 All bolts and nuts shall conform to IS: 6639-1972 and shall be galvanized as per IS:1367 (Part

13) & IS: 2629-1985. All bolts and nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square with the shank, which must be perfectly straight.

20.2 Bolts up to M16 and having length up to 10 times the diameter of the bolt should be

manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. Shear strength of bolt for 5.6 grade should be 310 MPA minimum as per IS:12427. Bolts should be provided with washer face in accordance with IS:1363 (Part – I) to ensure proper bearing.

20.3 Nuts should be double chamfered as per the requirement of IS:1363 (Part – III)- 1984. The

Bidder/manufacturer should ensure that nuts should not be over tapped beyond 0.4 mm oversize on effective diameter for size up to M16.

20.4 Fully threaded bolts shall not be used. The length of the bolt shall be such that the threaded

portion shall not extend into the place of contact of the component parts. 20.5 All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the

firm gripping of the component parts but no further. It shall be ensured that the threaded portion of the bolt protruded not less than 3 mm and not more than 8 mm when fully tightened.

20.6 All nuts shall fit and tight to the point where shank of the bolt connects to the head. Flat

washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electro-galvanized. Thickness of washers shall conform to IS: 2016-1967.

20.7 The Bidder shall furnish bolt schedules giving thickness of components connected the nut and

the washer and the length of shank and the threaded portion of bolts and size of holes and any other special details of this nature.

20.8 To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time

its diameter. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling.

20.9 To ensure effective in-process quality control it is essential that the manufacturer should have

all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities etc, in-house. The agency should also have proper Quality Assurance system which should be in line with the requirement of this specification and IS –14000 services Quality System standard. Fasteners of grade higher than 8.8 are not to be used.

20.10 RAW MATERIALS MS round 16mm / 12mm used shall be tested for quality as per IS:2062 Gr. “A”.

i. SPECIFICATION OF FINISHED PRODUCTS: Bolts & Nuts shall be ISI Marked Mild Steel of galvanized Grade “B” and shall be round with hexagonal head. Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished and shall have metric threads as per IS:4218-1967 with its latest amendments. Dimensions of the bolts & nuts and tolerances should conform to IS:1363 with their latest amendments in all respect. The eccentricity and angular errors of various elements shall be within specified limits as per IS:1367-1967 with its latest amendments. The bolts & nuts shall be free from forging and threading defects such as cuts, splits, burns, bulging, taper, eccentricity, loose fill etc. which may affect their serviceability. Bolt head and nut shall be chamfered on one face only and other face shall be machined made.



Mechanical property requirement of tester shall conform to IS:1367 (Part-III)-1979 property class 4.6 for bolts & property class-5 for nuts as per IS:1367 (Part VI) – 1980. Bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual bags of 50 kgs.

ii. ACCEPTANCE TESTS

The Bidder/manufacturer shall furnish test certificate from his own/recognized Govt. Laboratory giving the results of tests as per IS:1367 (Part-III) –1979 & IS:1367 (Part-VI) -1980 witnessed by the Employer’s representative for each lot under inspection. The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given below:- Dimensional particulars (Sampling in accordance with IS:2614 for both bolts & nuts (tolerance as per drawing). Tensile strength test on full size (for bolts min. 400 N/ Sq.mm and for Nuts. Proof Stress (Min 610 N/Sq. mm). Power load test on full size bolts and M-12-51400 N for 15 Sec. (with Head soundness tests for bolts (no fracture). Brielle hardness tests or Rockwell Hardness or Vickers’s Hardness tests for bolts min-114 & max. 209 or min. 67 & max. 95 or min. 120 & max. 220 respectively. For nuts Vicker’s Hardness min. 130 & max. 302.

Galvanizing test- mass of zinc 20.11 PRE-DESPATCH INSPECTION AND TEST

The contactor shall arrange to carryout acceptance tests in presence of Board’s inspecting officer in his own laboratory. In case testing facilities are not available at his works he will make necessary arrangements for carrying out these tests at a Govt. recognized lab at his own expense(s) and will provide all testing arrangement for Board’s representative to witness the tests.

iii. MARKINGS

On the bolt head, there shall be identification marking of the manufacturer as well as property class “4.6”. If possible property class “5” shall be marked on Nuts also.

GUARANTEED TECHNICAL PARTICULARS of Nut & Bolt

No Particulars 16 mm dia 17 mm dia

200 mm

160 mm

140 mm

90 mm

65 mm

40 mm

140 mm

120 mm

100 mm

I Tenderer Name

Ii Tenderer Address

Iii Dimensional particulars with reference to the enclosed drawing. These should conform to the ISS: 1363 Part-1,2,3-1984 with latest amendment & sampling in accordance with the IS:2614-1969

D To be indicated by the Bidder/manufacturer M To be indicated by the Bidder/manufacturer E To be indicated by the Bidder/manufacturer S To be indicated by the Bidder/manufacturer B To be indicated by the Bidder/manufacturer K To be indicated by the Bidder/manufacturer Pitch of thread Tolerance of

nominal length To be indicated by the Bidder/manufacturer



Iv a) Tensile strength of bolts (in N/mm. Sq.)

--------------------------400/N mm2-------------------------------------

b) Tensile strength of Nuts (in N/mm.Sq.)

--------------------------Not applicable --------------------------

V a) Result of proof load test on bolt Min 35300 N Min 19000 N b) Result of proof load test on nut Min 95800 N Min 51400 N Vi Result of head soundness test No fracture Vii Confirm that threads are as per

IS:4218 1967 (metric threads) To be indicated by the Bidder/manufacturer

Viii Results of Brinell/Rockwell/Vicker’s/hardness test for bolts

Min – 114 & Max. 209, Min 67- Max 95, Min. – 120 & Max. 220 (respectively)

Ix Result of Vickers’s hardness test for nuts

Min 130 Max 302

X Results of yield stress test for Bolts

To be indicated by the Bidder/manufacturer

Xi Percentage elongation after fracture


Xii Confirm that Bolts and Nuts are ISI marked


DIMENSIONAL PARTICULARS OF BOLTS & NUTS AS PER IS: 1363 (PART – 1,2 & 3) OF IS 1984 (Drawing Not to Scale) Sl.

Symbol

1 D (Bolt shank diameter)

2 M (Nut thickness) 3 E (Width across

concerns) 4 S (Width across

flats) 5 B (Length of

thread) 6 F (Thickness of

bolt head)

Size of Bolts & Nuts

D M E* S* B K

Nom

Max.

Min.

Nom

Max.

Min.

Min. Nom

Max.

Min. B1

B2

B3

Nom

Max.

Min. Pitch thread

16mm dia

16 16.7

15.3

15 15.9

14.1

26.17

24 24 23.16

38

44

57

10

10.75

9.25 2.00

12mm dia

12 12.7

11.3

11.3

12.2

10.4

19.85

18 18 17.57

30

36

49

7.5

7.95

7.05 1.75

*for Bolts & Nuts both E, S & Pitch are same NOMINAL LENGTH TOLERANCE 20 - 90 mm - ± 2.0 mm Use B1 for < 125 mm i.e. for length upto 125mm 91 - 200 mm - ± 3.0 mm Thread B2 for > 125 mm i.e. for 200 mm i.e. for length between 126 to 200mm Length B3 for > 200 mm i.e. for length above 200 mm



21.0 EARTHING COIL

Earthing Coils shall be fabricated from soft GI Wire Hot Dip Galvanized. The Hot Dip galvanized wire shall have clean surface and shall be free FROM paint enamel or any other poor conducting material. The coil shall be made as per REC constructions standard J-1 (drawing enclosed). The Hot Dip galvanizing shall conform to IS:2629-1985, IS: 2633-1986 and IS: 4826-1979 with latest amendments. Galvanizing should be heavily coated and should stand for the following tests.

21.1 Galvanizing Tests

i) Minimum Mass of Zinc a) ON GI Wire used 280 gm/m2 b) After Coiling – 266 gm/m2. The certificate from recognized laboratory shall be

submitted towards mass of zinc. ii) Dip Test

Shall stand 3 dips of 1 minute and one dip of ½ minute before coiling and 43 dips of 1 minute after coiling as per IS:4826-1979.

21.2 THE DIMENSIONAL REQUIREMENT SHALL BE AS FOLLOWS

a) Nominal dia of GI Wire 4 mm (Tolerance + 2.5%) b) Minimum no. of turns – 115 Nos. c) External dia of Coil (Min) – 50 mm d) Length of Coil (Min) – 460 mm e) Free length of GI Wire at one end coil (Min.) – 2500 mm

The turns should be closely bound. Weight of one finished Earthing Coils (min.) – 1.850 Kg. Adhesion test – As per IS: 4826 – 1979.

HOT DIP GALVANIZED EARTHING COILS OF MIELD STEEL WIRE 4 MM DIA

S. NO. PARTICULAR REQIURED To be categorically specified

1 Manufacturer Name & Address 2 Standard according to which Earthing

coil shall be manufactured and tested IS-2062/1984 IS-2629/1996 IS-2633/1972 IS-4826/1979 with latest amendment

3 Tolerance in dimensions (if any) To be indicated by Bidder/manufacturer

4 Dia A Dia of GI wire (mm) 4mm + 2.5% B Minimum no. of turns 115 Nos. C External dia of coil 50 mm D Length of coil (Min) 460 mm E Free length of GI Wire @ end of the

coil. 2500 mm

5 Weight of Earthing Coil (Min) 1.850 Kg



22.0 PRESTRESSED CEMENT CONCRETE POLES FOR 11 KV & LT. LINES (8.0 meter long / 140 kgs.):

22.1 SCOPE: This specification covers PCC poles with an overall length of 8.0 m, suitable for use in

overhead 11 kV and L.T. power lines and double pole structures for 11/0.4 kV substations. 22.2 APPLICABLE STANDARDS: Except when they conflict with specific requirements in this specification, the poles shall

comply with the relevant provisions made in the following Indian Standard Specification. a) IS:1678-1978, Specification for pre-stressed concrete poles for overhead power, traction and

telecommunication lines. b) IS:2905-1966. Methods of test for concrete poles for over-head power and telecommunication

lines. c) IS:7321-1974. Code of practice for selection, handling and erection of concrete poles for over-

head power and telecommunication lines.

22.3 TERMINOLOGY: For the purpose of this standard, the following definitions shall apply:- AVERAGE PERMANENT LOAD: That fraction of the working load, which may be considered or long duration over a period of one year. LOAD FACTOR: The ratio of ultimate transverse load to the transverse load at first crack. TRANSVERSE: The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. TRANSVERSE LOAD AT FIRST CRACK: For design, the transverse load at first crack shall be taken as not less than the value of the working load.

WORKING LOAD: The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600 mm below the top with the other end of the pole planted to the required depth as intended in the design. ULTIMATE FAILURE: The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the pre-stressing tendon or permanent stretching of the steel in any part of the pole. ULTIMATE TRANSVERSE LOAD: The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the but end of the pole planted to the required depth as intended in the design. 8.0 M POLES: These poles shall be used at tangent locations for 11 kV and LT lines in wind pressure zones of 50 kg/m2, 75 kg/m2 and 100 kg/ m2 in accordance with REC construction standards referred to in the following table:-

Pole Length Line Description Ref. to Rec.

Construction Standards.

8.0 M 11 KV Line with Earth Wire A-5 LT Lines, Vertical Formation B-6

The adoptable spans shall be as per REC construction standards A-8 (for 11 kV lines) and B-8 (for L.T. lines)

22.4 MATERIALS:

CEMENT: The cement used in the manufacture of pre-stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS:269-1976 (Specification for



ordinary and low heat Portland cement) or IS:8041 E–1978 (Specification for rapid hardening Portland cement). AGGREGATES: Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS:383-1970 (specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregate shall in no case exceed 12 mm. WATER: Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. ADMIXTURES: Admixtures should not contain calcium chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. PRESTRESSING STEEL: The pre-stressing steel wires, including those used as un-tensioned wires (see Annex. 1), should conform to IS:1785(Part-I)-1966 (Specification for plain hard-drawn steel wire for pre-stressed concrete. Part –I cold drawn stress relieved wire), IS:1785 (Part–II)–1967 (Specification for plain hard-drawn steel wire)., or IS:6003-1970 (Specification for intended wire for pre-stressed concrete). The type designs given in Annexure – I are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 175 kg/ mm2. The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS:1343-1980 (code of practice for pre-stressed concrete) and IS:456-1978 (code of practice for plain and reinforced concrete), subject to the following special conditions;

a) Minimum works cube strength at 28 days should be at least 420 kg/cm2.

b) The concrete strength at transfer should be at least 210-kg/ cm2.

c) The mix should contain at least 380 kg. Of cement per cubic mater of concrete.

d) The mix should contain as low water content as is consistent with adequate workability. If

it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ration is maintained.

22.5 DESIGN REQUIREMENTS: The poles shall be designed for the following requirements:

a) The poles shall be planted directly in the ground with a planting depth of 1.5 meters. b) The working load on the poles should correspond to those that are likely to come on the

pole during their service life. Designs given in drawing are for 140 kg. And 200 kg. Applied to 0.6 m from top.

c) The factor of safety for all these poles shall not be less than 2. 5.

d) The average permanent load should be 40 % of the working load.

e) The F.O.S. against first crack load shall be 1.0.

f) At average permanent load, permissible tensile stress in concrete shall be 30 kg. Cm2.

g) At the design value of first crack load, the modules of rupture shall not exceed 55.2 kg/cm2 for M-420 concrete.

h) The ultimate moment capacity in the longitudinal direction should be at least one fourth of

that in the transverse direction.

i) The maximum compressive stress in concrete at the time of transfer of pre-stress should not exceed 0.8 times the cube strength.

j) The concrete strength at transfer shall not be less than half the 28 days strength

ensured in the design, i.e. 420 x 0.5 = 210 kg. / cm2

For model check calculations of the design of poles, reference may be made to the REC “Manual on Manufacturing of solid PCC poles, Part- I – Design Aspects.”



DIMENSIONS AND REINFORCEMENTS: The cross-sectional dimensions and the details of pre-stressing wire should conform to the particulars given . The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4 of this specification and in accordance with the construction practices adopted by the State Electricity Boards.

22.6 MANUFACTURE: All pre-stressing wires and reinforcements shall be accurately fixed and maintained in position during manufacture. The un-tensioned reinforcement should be held in position by the use of stirrups, which should go round all the wires. All wires shall be accurately stretched with uniform pre-stress in each wire. Each wire or group of wires shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength.

22.6.1 COVER: The cover of concrete measured from the outside of the pre-stressing tendon shall be normally 20 mm. 22.6.2 WELDING AND LAPPING OF STEEL: The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire.

22.6.3 COMPACTING: Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted.

22.6.4 CURING: The concrete shall be covered with a layer of sacking, canvas, Hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of pre-stress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit; the interval should depend on the atmospheric humidity and temperature.

22.6.5 DE-Tension: The pre-stressing wires shall be de-tensioned only after the concrete has attained the specified strength at transfer (i.e. 210 kg/cm2). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS:1343-1960 (code of practice for pre-stressed concrete). The manufacturer shall supply when required by the Employer or his representative, result of compressive test conducted in accordance with IS:456-1964 (code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the Employer so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS:456-1964 (code of practice for plain and reinforced concrete).

The de-tensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of de-tensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be de-tensioned or released by cutting the pre-stressing wires using flames or bar croppers while the wires are still under tension.

22.6.6 Handling & Transport: Separate eyehooks or holes shall be provided for handling and transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the board face of the pole.

Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported of timber sleepers located at 0.15 times the overall length, measured from the end. The timber supports in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the overall length from the ends. The erections of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole.



EARTHING: Earthing shall be provided by having a length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. at 250 mm. from top and 150 mm below ground level. The earth wire shall not be allowed to come in contact with the pre-stressing wires. GENERAL: For further details on the process of manufacture, a reference may be made to REC “Manual on Manufacturing of Solid PCC Poles Part II Manufacturing Aspects”.

22.7 TESTS

TRANSVERSE STRENGTH TEST: Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid-hardening cement only on the completion of 14 days, after the day of manufacture. The pole may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-hanging portion of the pole may be supported on a movable trolley or similar device. The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.e. 1.5 M. Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The deflection at this load shall be measured. A pre-stressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80% of the minimum ultimate transverse load and thereafter increased by 5 % of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to pre-stressed concrete pole at the point of failure shall be measured to the nearest five Kg. MEASUREMENT OF COVER: After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meters from the butt end of the pole, the second within 0.6 meter from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than 21 mm from the specified cover. The individual values should not differ by more than (+) (-) mm from specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and pre-stressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably.

22.8 SAMPLING AND INSPECTION

SCALE OF SAMPLING: Lot: In any batch, all poles of the same class and same dimension shall be grouped together to constitute a lot. Sub-lot: If the numbers of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of a sub-lot shall be determined on the basis of the performance of samples selected from it. The number of poles to be selected from a lost or a sub-lot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table:-



These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every nth pole may be included in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size.

22.9 NUMBER OF TESTS All the poles as selected in 16.8 shall be tested for overall length, cross-section and uprightness. The tolerance shall be (+) (-) 15 mm on overall length, (+) (-) 3 mm on cross sectional dimensions and 0.5 % on uprightness. The number of poles to be tested for transverse strength test shall be accordance with col. 4 of the above table. These poles may be selected from those already tested in 16.8.

22.10 CRITERIA FOR CONFORMITY A lot of sub-lot shall be considered as conforming to this specification if the conditions are satisfied. The number of poles which does not satisfy the requirements of overall length, cross-section and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 16.8 if the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements, and those not satisfying the requirements shall be rejected. All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirement of this test.

22.11 MARKING

The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position.

a) Month and year of manufacture b) Transverse strength of pole in kg. c) Maker’s serial no. and mark. d) Word MPEZ.

Guaranteed technical particulars of 8 Mtr/140 Kgs long PCC Poles

1 Length of Pole 8 Meter To be categorically specified by the Bidder

2 Weight of Pole 380 Kg 3 Top Dimensions (mm) 100 mm x 100 mm 4 Bottom Dimensions (MM) 276 x 100 mm 5 No of lifting Hooks Two on same side 6 No. of 4 mm HT wire 10 no. 7 Working Load 140 Kgs. 8 Earthing Wire 1 9 Planting Depth (mm) 1500

SAMPLE SIZE AND CRITERION FOR CONFORMITY

Size of lot or Sub-lot

Dimensional Requirement No. of Poles for Transverse Strength Test

Sample Size Permissible No. of Defective Samples

Up to 100 10 1 * 101 to 200 15 1 3 201 to 300 20 2 4 301 to 500 30 3 5 * The number of Poles to be tested shall be as approved by the Employer.



23.0 GALVANIZED MS STAY SETS (16 MM DIA) 23.1 (A) 16 MM DIA STAY SETS GALVANIZED (i) The stay sets (Line Guy set) will consist of the following components :-

iv. ANCHOR ROD WITH ONE WASHER AND NUT

Overall length of rod should be 1800 mm to be made out of 16 mm dia MS Rod, one end threaded upto 40mm length with a pitch of 5 threads per cm and provided with one square MS washer of size 40x40x1.6mm and one MS hexagonal nut conforming to IS:1367-1967 & IS:1363-1967. Both washer and nut to suit threaded rod of 16mm dia. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated in the enclosed drawing No.DISCOM/EZ-29 and details of welding are indicated below.

v. ANCHOR PLATE SIZE 200x200x6MM

To be made out of MS plate of 6mm thickness. The anchor plate should have at its centre 18mm dia hole.

vi. TURN BUCKLE : (A) EYE BOLT WITH 2 NUTS

To be made of 16mm dia MS Rod having an overall length of 450 mm, one end of the rod to be threaded upto 300 mm length with a pitch of 5 threads per cm and provided with two MS Hexagonal nuts of suitable size conforming to IS:1363-1967 & IS:1367-1967. The other end of rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality welding as described below.

(A) BOW WITH WELDED ANGLE

To be made out of 16mm dia MS rod. The finished bow shall have an overall length of 995mm and height of 450 mm as shown in the enclosed drawing No.DISCOM/EZ-29, the apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a MS angle 180mm long having a dimension of 50x50x6mm. The angle shall have 3 holes of 18mm dia each as per drawing No.1 enclosed herewith. Details of welding are indicated below and also shown in the enclosed drawing No. 4.

vii. THIMBLE

To be made on 1.5 mm thick MS sheet into a size of 75x22x40mm and

shape as per details given in attached drawing No.1. 23.2 WELDING

The minimum strength of welding provided on various components of 16mm dia stay sets shall be 3100 kg. Minimum 6 mm fillet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS:823-1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay sets shall be as shown in the enclosed drawing No.4. Welding if, found short in lengths or not done properly as required shall be rejected.

23.3 THREADING

The threads on the Anchor Rod, Eye Bolt & Nuts shall be as per specification IS: 4218-1967 (ISO Metric Screw Threads). The nuts shall be conforming to the requirement of IS:1367-1967 & have dimensions as per IS:163-1967. The mechanical property requirement of fasteners shall conform to property clause .6 each for anchor rod & Eye bolt and property clause 4 for nuts as per IS:1367-1967.

AVERAGE WEIGHT OF FINISHED 16MM STAY SETS 7.702 KG. (MINIMUM) (EXCLUDING NUTS THIMBLES AND WASHERS) 8.445 KG. (MAXIMUM)

i. TEST CERTIFICATE



The Bidder/manufacturer shall be required to furnish the test certificates from Govt./Recognized testing laboratory giving results of following tests along with their offer & inspection report of material of first lot in individual size separately for 16mm & 20mm sizes in case of regular Bidder/manufacturer.

Tensile Load of 3100 Kg/4900 Kg. Applied for one minute on the welding & maintained for one minute for 16 mm and 20 mm dia stay sets respectively. In view of non submission of above test certificates inspection report shall not be acceptable.

ii. IDENTIFICATION MARK

All stay sets should carry the identification mark of the manufacturer. For this, the firm must engrave identification mark of about 3 capital letters. This should be engraved on the stay plate and on stay rods to ensure proper identification of the materials. On account of this, no extra charges will be paid.

iii. The nuts should be of a size compatible with threaded portion of rods and there

should be no play or slippage of nuts. iv. Welding wherever required should be perfect and should not give way after erection.

NOTE i) Please see attached drawing No.1,2,3 & 4 for details of components and

welding. ii) No assistance will be given in arranging the raw material by the Board.

v. TOLERANCES

The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16mm dia excluding nuts, thimbles and washers shall not be less than the weight specified above :-

No Item Section Tolerances Fabrication Tolerances Material

1 Anchor Plate 6mm thick + 12.5% - 5%

200x200mm + 1% MS Plate 6mm thick

2 Anchor Rod 16mm dia + 5% - 3%

Length 1800mm + 0.5% MS Round 16mm dia

Rounded Eye 40 mm inside dia + 3%. Threading 40mm+11% - 5

MS Round 16mm dia

3 Turn Buckle Bow

16 mm dia + 5% - 3%

Length 995mm + 1% 16mm dia

MS Round 16mm dia

Length 180mm + 1% 50x50x6mm

MS Angle

4 Eye Bolt Rod 16mm dia + 5% - 3%

Length 450mm + 1% Threading 300mm + 1% Round Eye 40mm inside dia + 3%

MS Round 16mm dia

18.4 The complete stay set shall be galvanized as per the relevant IS specification IS: 2629-1985 & IS: 4759-1986. The Manufacturer/Bidder/manufacturer shall furnish the tests report for the stay set as well as galvanizing from NABL accredited Laboratory.

MS GUY/STAY SETS 16 MM DIA (Hot Dip Galvanized)

S. No. Description Requirement To be categorically specified

1 Name of Bidder 2 Manufacturer Name & Address

3 Anchor Rod

a Overall length of Anchor Rod Length 1800mm + 0.5% b Length of threaded portion 40mm +11% -5% c Pitch of Thread 5.00



S. No. Description Requirement To be categorically specified

d Size of MS Nut Bolt, Square MS Washers confirming to IS 1367 (1967) and IS 1363 (1967)

16 mm Sq washer 40x40x1.6 mm

e Inner dia of round eye made at other end of the rod

40 mm + 3%

4 Anchor Plate

A Size of the MS anchor plat 200x200mm + 1%

B Dia of the hole made at the centre of the plate

18mm

5 Turn Buckle (A) Eye Bolt with two nuts

a Dia of the eye bolt 16 mm dia + 5% & - 3%

B Length of the eye bolt 450mm + 1%

C Length of the threaded portion of the bolt

300mm + 1%

D Pitch of ht thread 5.00

E Size of MS Nut Bolt, confirming to IS 1363 (1967) and IS 1367 (1967)

Yes

F Inner dia of the circular eye made at other end of the bolt

40 mm + 3%

(B) Bow with welded channel

A Dia of the MS rod used for bow 16 mm dia + 5% & - 3%

B Overall length and height of the bow

995 mm + 1% 450 mm + 1%

C Magnitude of the angle in radians by which bow is bended at the top

10 R

D Length and size of the MS channel welded at the order end of the bow

180 mm + 1% 50x50x6.0 mm Angle

E Number of holes made in the MS channel / Angle

3

F Dia of the holes 18 mm (3 Nos.)

6 Thimble

A Thickness of the MS sheet used for thimble

1.5 mm

B Size of the thimble 75x55x40 mm

7 Minimum strength of the welding provided on various components of Guy/Stay sets (IS: 823 / 1964)

3100 Kg.

8 Average weight of finished Guy/Stay sets excluding nuts, thimble and washers

A Minimum 7.702 Kg.

B Maximum 8.445 Kg



24.0 HOT DIP GALVANIZED MS STRANDED WIRE

The hot dip galvanized MS Stranded wire of sizes 7/3.15 mm diameters shall conform to the relevant ISS specification as detailed below:

24.1 MATERIAL

MS Wire used for each strand shall have the chemical composition (maximum) Sulphur & Phosphorus – 0.055% and Carbon 0.25%. Zinc shall conform to grade Zen 98 specified ARE 209-1966 & ARE 2141-1968, 1979 with up to date amendments.

24.2 ZINC COATING

Zinc coating shall be in accordance with IS:4826-1979 (heavily coated hard quality Grade-4 as per table-1) with up to date amendments.

24.3 GALVANISING

Hot dip galvanizing shall be as per IS:2629-1985 & IS:4826-1979 with up to date amendments. 24.4 UNIFORMITY OF ZINC COATING

Uniformity of Zinc coating shall be determined as per IS:2633-1986 with up to date amendments.

24.5 TENSILE PROPERTIES

Tensile properties of each strand ensuring MS Wire mechanical properties as per IS:280-1972 (Cl.8.1 to 8.3) and after galvanizing each wire shall be of tensile strength minimum 700N/mm2 (71 Kgs/mm2). Tensile strength, bending load, lay & elongation of each wire and full strand shall conform to IS: 2141-1968 & IS: 2141-1972 in the tensile grade given above).

24.6 CONSTRUCTION Construction shall be as per IS: 2141-1979 (Cl. 5.3.1 to 5.3.3) 24.7 FREEDOM FROM DEFECTS Freedom from defects be ensured as per IS: 2141-1979 (clause 4.1.6 respectively). 24.8 TESTS ON WIRE BEFORE MANUFACTURE As per IS:2141-1979 (Col.7.1 to 7.2.2) shall be done. 24.9 PACKING

Each coil shall be between 50-100 Kgs. Packed as per IS: 2141-1968 (Cl. 9.1) 6594-1979 & 2141-1979 (Cl. 11).

24.10 MARKING As per IS: 2141-1968 (Cl.8.1 to 8.1.1) and IS: 2141-1979 (Cl.10 & 10.1) and as per latest amendments is required.

GTP of GALVANIZED MS STRANDED WIRES 7 / 3.15mm

S. No.

Particulars Requirement To be categorically specified

1 Number of Wire in Strand 7 2 Nominal Diameter of each Wire 3.15 mm 3 Tolerance in diameter + 2.5%



S. No.


4 Sectional area of each Wire 12.89 5 Minimum Tensile Strength of each wire before stranding

(corresponding to grade 4) 1.4 Kgf/ mm2

6 Minimum breaking load of each wire before stranding 556 7 Elongation Test – The elongation shall be subject to a reduction of not

more than 10%

8 Weight of zinc gms/sq.mm of each wire tested i) Before Stranding 240 ii) After Stranding 228 9 Type of Coating on each Wire Heavy 10 Variety of each Wire Hard 11 Ductility Test (Wrap Test) of each wire before manufacture a) Complete Turns of Wrap 8 b) Dia of mandrel on which to be wrapped 3.15mm 12 Min. Breaking Load after Stranding 3698 Kgf 13 Elongation Test (Min. % elongation corresponding to grade 4) 6 % 14 Length of lay of strand Min. 113.4mm Max. 170.1mm 15 Number of dips the coating each wire is able to withstand at 18 ± 2ºC a) Before Stranding 2 dips of 1

minute

b) After Stranding 1 dips of ½ minute

16 Freedom from Defects As pr ISS 17 Chemical Composition. The MS Wire used shall not exceed a) Sulphur 0.055% b) Phosphorous 0.055% c) Carbon 0.25 %



25.0 ANTI-CLIMBING DEVICES

In order to prevent unauthorized persons from climbing any of the supports of HT & LT lines without the aid of a ladder or special appliance, certain anti-climbing devices are provided to the supports. Barbed wire binding is to be adopted for this purpose at a distance of 30 to 40 cm at a height of 3.5 to 4 m from ground level. The barbed wire shall conform to IS: 278 (Grade A1). The barbed wired shall be given chromating dip as per procedure laid down in IS:1340. At least 3.5 kgs barbed wire is to be used per pole for the purpose.

26.0 HOT DIP GALVANISED GS SOLID WIRE

The hot dip galvanized MS Solid wire of sizes 5 mm, 4 mm and 3.15 mm diameters shall conform to the relevant ISS specification, briefed here below: -

26.1 MATERIAL

The Mild Steel wire shall have the chemical composition maximum sulphur - .055%, Phosphorus – 0.055%, Carbon 0.25%. Zinc shall conform to grade Zen 98 specified in IS:209-1966 & IS: 4826-1979 with up to date amendments.

26.2 ZINC COATING Zinc coating shall be in accordance with IS: 4826-1979 (Cl.4.2.1) for heavily coated hard quality. 26.3 GALVANIZING

Galvanizing shall be as per IS:2629-1985 and IS:4826-1979 with up to date amendments. 26.4 UNIFORMITY OF ZINC COATING

Uniformity of Zinc coating shall be determined as per IS:2633-1972 with up to date amendments.

26.5 TENSILE PROPERTIES

The tensile strength of the wire after, galvanizing shall be between 55-95 Kg/Sq.mm (heavily coated Hard as per IS:4826-1979 Tables-1) ensuring MS wire Mechanical properties as per IS:28-1972 8.1 to 8.3.

26.6 FREEDOM FROM DEFECTS To be ensured as per IS: 2629-1985 (Cl. 6.1) & IS:4826-1979 (Cl. 4.3) & with up to date

amendments. 26.7 TESTS

During the process of manufacture/ fabrication and finish all tests for chemical, mechanical, galvanizing as per IS:280-1979, IS:1521-1972, IS:1755-1961, IS:6745-1972 & IS:4826-1979 be carried out. Test certificate towards, chemical composition (as per above) shall be submitted for each lot offered for inspection. The following tests shall be conducted in presence of owner’s representative.

1. Visual Physical inspection and measurement of specified dimensions. 2. Coating test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1979 & IS: 6745-

1972. 3. Adhesion test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1969 & 1979 –

IS:6745-1972. 4. Tensile strength and breaking load and elongation determined as per IS:1521-1972 with up to

date amendments.



26.8 PACKING

Packing shall be as per IS:280-1979 (Cl.3.1) and each coil shall be between 50-100 Kg. 26.9 MARKING As per IS:280-1972 (Cl.14.1 & 14.1.1) is required.

GTP of GALVANIZED SOLID WIRE 5 mm

S. No.


1 Nominal Diameter of Wire 5 mm

2 Tolerance in diameter + 2.5% 3 Sectional Area Sq. mm. 19.625 4 Tensile Strength a) Min. Kgf/mm2 55 b) Max. Kfg/mm2 95 5 Minimum breaking load (Kgf) 10/9.5 6 Type of coating Heavy / Medium / Light HEAVY 7 Variety Hard/Soft HARD 8 Weight of Zinc Coating (Gms/Sq. Mtr.) Min. 275 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 DIPS OF 1 MIN &

1 DIP OF ½ MINUTE

10 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength

a) Min. complete turn of wrap 10 b) Dia of mandrel on which wrapped 16 TIME OF DI 30

MM

11 Bend Test a) Angle 90 b) Dia Round a formet to be bent 10 MM 12 Freedom from defect 13 Chemical composition the MS Wire used shall not exceed Sulphur 0.055%

To be indicated

Phosphorous 0.055% Carbon 0.25 % GTP of GALVANIZED SOLID WIRE 4 mm

S. No.


To be categorically specified by the tenderer

1 Nominal Diameter of Wire 4 mm

2 Tolerance in diameter + 2.5% 3 Sectional Area Sq. mm. 12.56 4 Tensile Strength a) Min. Kgf/mm2 55 b) Max. Kfg/mm2 95 5 Minimum breaking load (Kgf) 690.8 6 Type of coating Heavy / Medium / Light HEAVY 7 Variety Hard/Soft HARD 8 Weight of Zinc Coating (Gms/Sq. Mtr.) Min. 260 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 DIPS OF 1 MIN

EACH


a) Min. complete turn of wrap 10 b) Dia of mandrel on which wrapped 24MM 11 Bend Test



S. No.


To be categorically specified by the tenderer

a) Angle NA b) Dia Round a formet to be bent NA 12 Freedom from defect 13 Chemical composition the MS Wire used shall not exceed Sulphur 0.055% amendments if any I.S. 226

To be indicated

Phosphorous 0.055% Carbon 0.25 %

GTP of GALVANIZED SOLID WIRE 3.15 mm

S. No.


1 Nominal Diameter of Wire 3.15 mm

2 Tolerance in diameter + 2.5% 3 Sectional Area Sq. mm. 7.789 4 Tensile Strength a) Min. Kgf/mm2 55 b) Max. Kfg/mm2 95 5 Minimum breaking load (Kgf) 428.4 6 Type of coating Heavy / Medium / Light HEAVY 7 Variety Hard/Soft HARD 8 Weight of Zinc Coating (Gms/Sq. Mtr.) Min. 240 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 DIPS OF 1

MIN EACH


a) Min. complete turn of wrap 10 b) Dia of mandrel on which wrapped 14 TIME OF DI

12.6 MM

11 Bend Test a) Angle NA b) Dia Round a formet to be bent NA 12 Freedom from defect 13 Chemical composition the MS Wire used shall not exceed Sulphur 0.055%

To be indicated

Phosphorous 0.055% Carbon 0.25 %



27.0 11 KV DO FUSE UNITS 27.1 SCOPE

This specification provides for manufacture, testing at works before dispatch and delivery of 11 KV DO Fuse units. This covers outdoor open, drop-out expulsion type fuses suitable for installation in 50Hz 11KV distribution system.

27.2 APPLICATION The D.O. Fuses are intended for use on Distribution transformers for protection/isolation of the same during overload or fault conditions.

27.3 APPLICABLE STANDARD Unless otherwise modified in this specification, the drop out fuse shall conform to IS: 9385 (Part-I to III) as amended from time to time.

27.4 DROP OUT FUSES The drop-out fuses shall be expulsion type. This shall be ‘D’ type and out-door lift off type suitable for manual operation by an operating rod from the ground level. The drop out operation will be angular in vertical plane. The equipment offered, shall be suitable for 11KV three phase 50 C/S solidly grounded earthed neutral systems. It shall be designed for a normal current rating of 200 Amps.

The drops out fuses are required with Post Insulators. These shall be suitable for mounting on the structure. The bracket/channel hardware for DO Fuses shall be provided with adequate sizes of nuts, bolts and washer for mounting on the structures.

27.5 POST INSULATORS

Each 11KV DO Fuse shall have two Nos 11 KV Post Insulators. The insulator shall conform to IS: 2544 -1973 with latest amendment. The porcelain used for manufacture of DO Fuse units shall be homogeneous, free from flaws or imperfections that might affect the mechanical or dielectric strength. They shall be thoroughly vitrified tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown color free from blisters, burns and other similar defects. Insulators shall be of the same rating and type and shall be interchangeable. The porcelains and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through range of temperature variation shall not loosen parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base pin shall be made of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base shall be properly cemented with insulators to give perfect grip. Excess use of cement shall be avoided. The Bidder/manufacturer/Manufacturer shall submit the type test certificate of DO Fuse along with certified copy of the drawing and other relevant technical guaranteed particulars. Each 11KV Post Insulators should have technical parameters as detailed below:-

Sl. Particulars 11KV i Nominal system voltage KV (rms) 11 ii Highest system voltage KV (rms) 12 iii Dry Power Frequency with stand voltage KV (rms) 35 iv Power Frequency puncture voltage KV (rms) 1.3 times the actual dry

flashover voltage v Impulse withstand voltage KV (rms) 75 vi Visible discharge voltage KV (rms) 9 vii Creep age distance in mm (minimum) 320 viii Cantilever strength (KN) 6.60



As stated above unless otherwise modified in this specification the drop out fuse set shall conform to IS:9385 (Part-I to III) and as amended from time to time.

27.6 RATED VOLTAGE

The rated voltage shall be 11KV for 11KV DO Fuses respectively.

27.7 RATED CURRENT The rated current shall be 200 Amp. for 11KV DO Fuses

27.8 RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE The rated lightning impulse withstands voltage both for positive and negative polarities shall be as given below:-

11KV a To earth and between poles 75 KV Peak b Across the isolating distance of fuse base 85 KV Peak

27.9 RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY AND WET)

VALUES FOR THE FUSE BASE a) To earth and between poles 28KV Peak 75KV Peak b) Across the isolating distance of 32KV Peak 80KV Peak

fuse base 27.10 RATED BREAKING CAPACITY

The rated breaking capacity shall be 8KA (A symmetrical). Submission of type test certificate of rated breaking capacity in case of 11KV DO FUSE Unit is essential.

27.11 MAIN CONTACTS The main contacts of the D.O. Fuse shall be suitable for heavy duty, properly aligned and made from Brass material. These shall have good finish and smooth surface and shall be silver-plated. All the sharp edges shall be rounded off. These contacts shall be so designed to withstand highest short circuit breaking current that may be encountered during service. In nutshell the contact assembly shall ensure.

1. Electrodynamics withstands ability during short circuit without any risk of repulsion of contact. 2. Thermal withstands ability during short circuits. 3. Constant contact pressure even when the lower parts of the insulator stacks are subjected to

tensile stresses due to linear expansion of connected bus bar or flexible conductors either because of temperature variation or strong winds.

4. Proper alignment to ensure smooth operation of D.O. Fuse without adjustment. 27.12 CONNECTORS

The connectors shall be made from Brass suitable for ACSR/AAAC Weasel. The connectors should be bolted type having 4 bolts & groove to hold the conductor. All brass parts should be silver plated for corrosion resistance and efficient current flow. All ferrous parts should be hot dip galvanized as per the latest version of IS: 2629-1985 and IS: 4579-1984. Nuts and bolts shall conform to IS:1364 and should be hot dip galvanized. Spring washer should be Electro galvanized.

27.13 FLY NUTS These shall be provided at both the ends of SRBP tube for tightening the fuse elements. The nut shall be provided with one flat washer of 25mm dia. The arrangement shall be made to ensure that the fuse wire runs centrally inside the SRBP tube after tightening.



27.14 SPRING STRIPS

The spring strips shall be of phosphone bronze multiline brush type having a high pressure contacts and should retain its tension under minimum continuous service current of 200 Amps at 90 degree C.

27.15 OPERATING HOOKS The brass operating hook shall be fixed over the SRBP tube in such a way that the barrel can be removed for replacing the fuse element by operating rod from the ground level. The drop out fuse units shall operate efficiently; speed of operation shall not depend on the inclination of the fuse. However, the inclination of the fuse barrel shall be adjusted in such a way that the barrel does not drop by gravitational force.

27.16 D.O. BARRELS

The D.O. Fuse Barrels shall be made from SRBP and shall conform to BSS:1314. The agency shall furnish the test certificate for the fuse barrels offered for use in the drop out fuses along with each lot offered for inspection to the inspecting officer. The test certificates of SRBP barrel should indicate the following test results:-

i. Dimensión

a) External dia : b) Wall thickness : c) Internal dia :

ii. Max. wrapping in 12” length of the tube : iii. Axial electric strength (Proof test in oil : The barrel should with stand this test

at 90 degree C at 25KV rms 50 C/s) satisfactorily for one minute

iv. Radial electric strength (Proof test in oil : -do-

at 90 degree C at 19KV rms 50 C/s.) v. Surface electric strength (Proof test in air : -do-

at room temp.(32 degree C) at 14KV rms at 50 C/s. vi. Water absorption in 14 hours : vii. Resistance to Hot Oil : viii. Cohesion between layers : ix. Machine ability :

The agency should indicate the name of manufacturers of SRBP roles from where they will purchase the barrels to make available the test certificate. The barrels should have the properly to resist fire whenever the fuse is blown off. It should not catch fire easily during blowing off of fuse element inside the barrel which causes short time high temperature.


All materials used in the construction of the equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. The connecting of cap and pin with insulator should be perfect to avoid any kind of loosening. After cementing the insulator should be cured adequately in water to attain good gripping.

27.18 TESTS Each D.O. Fuse units shall strictly comply with requirement of all the type tests and shall be subjected to all routine tests stipulated in the relevant standard. All tests shall be made prior to



dispatch in the presence of the representative of the owner. No material should be dispatched without prior approval of the tests certificate by the owner. Along with the inspection report of D.O. Fuse Units, the agency should invariably furnish Routine Test Certificate of DO Fuse barrels & Post insulator from their respective manufacturers. Each DO Fuse shall be provided with name plate of size 2” x 1” on steel strip in case of 11KV and size 4” x 2” on steel channel and shall be either riveted bolted or pasted.

The following shall be indicated on the plate:-

1. Name of manufacturer 2. Sl. No. of the equipment 3. Rating……………………. Amps………………….Volts

Please note paper should not be used for name plate. Aluminum sheet of at least 2 mm thick embossed with above marking should be provided on the equipment for identification. The material should be packed in Wooden cartoons.

27.19 DIMENSION

Sl. Particulars Dimension of D.O. Fuse Unit in mm 11KV

1 Drawing No. To be submitted 2 G.S. Flat 245 x 25 x 6 3 G.S. Channel - 4 Fuse Barrels 330x25x14 5 Lower Contact Hinge of Barrel i Connectors 60x60x6 ii Hinge Contact Length 95 iii -do- Width 85 iv Thickness of Hinge Outer 5 Inner 4 6 Barrel take out hook i Width 25 ii Thickness 4 iii Length 30 iv Inner dia meter 25 v Thickness between inner outer dia 3 mm 7 Operating Hook i Width 18 ii Thickness 3 iii Inner Radius 19 iv Outer Radius 22.5 8 Female contact i Main contact width 65 ii Strip thickness 1.5 iii Strip Length 100 iv Width 20 v Female contact height 75 9 Female contact Holder i Length 74 ii Upper width 34 iii Lower width 40 10 Creep age of insulator 320

G.T.P of 11 KV D.O. FUSE UNITS

S. No.




S. No.


1 Type, make & country of origin 2 Maximum permissible continuos service voltage

(KV) 12 KV

3 Power Frequency withstand test voltage (One Minute)

i Dry KV 35 KV ii Wet KV 35 KV 4 Impulse withstand test voltage of completely

assembly unit within 1.2/50 micro second impulse wave against ground KV (Peak)

75/85 KV

5 Particulars of the main contact a) Type High pressure spring

strip

b) Material Brass & Cu alloy c) Surface Treatment & Thickness Silver plated 15

microns

6 Continuous Current Rating (Amps) 200 7 Breaking Capacity 8 KA Asymmetrical 8 Type Test Report for Thermal Limited Current 50 Deg. C 9 Type of Mounting (Bracket/Channel) Bracket type 10 Details of Connectors provided Made from Brass

suitable for AAA conductor

11 SRBP Barrels conform to BSS 1314 12 Particulars of Post Insulators i Type 11 KV Post insulator ii Make ISI make iii Strength 6.6 KN Iv Weight To be provided by Bidder/manufacturer V No. of Units per Stack One vi Diameter of Shed mm 162mm vii Height of Stack mm 254 mm viii Puncture voltage KV 1.3 times the actual dry flash over voltage Ix Creep age Distance mm 320 mm X One minute Power Frequency Dry withstand voltage

KV (rms) 35

xi Power Frequency Flashover voltage KV (rms) 70 xii Impulse flashover voltage KV (Peak) 105 xiii Impulse withstand voltage KV (Peak) 80 13 Applicable Standard specifications IS:9385 14 Applicable Drawing



28.0 PVC INSULATED AND PVC SHEATHED CABLES THREE

AND A HALF CORE, 25 SQ.MM. 28.1 SCOPE

The specification covers the design, manufacture and testing of “ISI” marked 1100 volt grade, three and a half core 25 sq mm. Aluminum conductor, unarmored PVC Insulated, PVC sheathed cable suitable for outdoor use.

28.2 APPLICABLE STANDARD

All the cables shall conform to the requirements of following standards with latest amendments, if any :- i) IS:694 -1990 - PVC Insulated Cables for working voltages upto and including 1100 V ii) IS:8130 -1984 - Specification for conductors for insulated Electric cables. iii) IS:5831 -1984 - Specification for PVC Insulation and sheath of Electric cables. iv) IS:10810-1984 - Methods of test for cables v) IS:4905 -1968 - Methods for random sampling

28.3 GENERAL TECHNICAL REQUIREMENT 28.3.1 CONDUCTOR

Aluminum conductor used in cables shall comply to the requirement to IS:8130-1984 with latest amendments and shall be in accordance with clause 4.2, 9.0, 9.1., 9.1.1. of IS:694-1990 with latest amendments. The conductor shall be stranded type conforming to Class-2 of IS: 8130-1984 for three and a half core 25 sqmm cable.

28.3.2 PVC INSULATION

PVC Insulation used shall comply to requirement of IS: 5831-1984 with latest amendments.

28.3.3 PVC insulation shall be suitable for continuous conductor temperature of 70oC under normal operation. Insulation shall be of “Type A” PVC compound. The average thickness of insulation shall be not less than nominal value specified in table 5 of IS: 694-1990. The smallest of the measured values of thickness of insulation (te) shall not fall below nominal value (ti) specified in table 5 of IS: 694-1990 by more than (0.1mm + 0.1 ti). The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be possible to remove it without damage to the conductor.

28.3.4 SHEATH

The sheath shall be of type S71 PVC Compound conforming to the requirements of IS:5831-1984. The sheath shall be applied by extrusion over the insulation in case of Single Core Cables and over the laid up cores in multi-core cables. The Sheath shall be so applied that it fits closely on laid up cores and it shall be possible to remove it without damage to insulation. The color of sheath shall be black. The thickness of PVC sheath shall not be less than the nominal value (ts) specified in table-5 of IS:694-1990 and the smallest of measured value shall not below the nominal value (ts) specified in Table-5 of (IS:694-1990 by more than 0.2 mm Plus 0.2 ts.

28.3.5 CORE IDENTIFICATION

i) Core shall be identified by different coloring of PVC Insulation in accordance with Clause-11 of IS:694-1990 by following coloring of PVC Insulation:-



ii) Four Core - Red, Yellow, Blue and Black

28.3.6 IDENTIFICATION, PACKING & MARKING 28.3.7 Manufacturer’s Identification

In addition to manufacturer’s identification on cable as per clause 17.1 of IS:694-1990 following marking shall also be embossed over the sheath at every one meter. a) Outer cable layer should be sky blue, b) Cable size and voltage grade, c) ISI monogram, d) Word ‘MPPKVVCL’ The embossing and not printing shall be done, automatic in line throughout the length of the cable and shall be legible and indelible.

28.3.8 Packing & Marking

(a) The cable should be packed in coil of 500 Mtrs. lengths. The packing shall be robust enough for rough handling that is occasioned during transportation by Rail / Road.

(b) The cable should carry the following information on the reel or drum or contained in a label attached to it :-

i) Reference to Indian Standard IS:694-1990 ii) Manufacturer’s name, brand name on trade mark iii) Type of cable and voltage grade iv) Number of cores v) Nominal cross-sectional area of the conductor vi) Cable code vii) Color of core viii) Length of cable on the reel, drum or coil ix) Number of lengths on reel, drum or coil (if more than one) x) Direction of rotation of drum by means of an arrow xi) Approximate gross mass xii) The word suitable for outdoor use xiii) Country of Manufacturer & xiv) Year of manufacturer

(c) “ISI” certification Mark The cable packed coil (reel, drum) must bear ISI certification mark. In this connection, a certified Photostat copy of valid “ISI” Marking License rights duly attested must be submitted along with the Bid as documentary evidence.

28.3.9 Standard Length

The standard length of cable shall be 500 mtrs. A maximum of 5% (Five percent) of each consignment in short lengths varying from 100 (Hundred) meters and above shall be accepted. Balance quantity of order shall be supplied in 500 Mtrs. Length only. However, plus minus 1% tolerance in length shall be permitted. This shall be indicated clearly and on individual coil.

28.4 TESTS

Following type tests, acceptance tests and routine tests are to be carried out in accordance with clause-15 of IS:694-1990 with its least amendments as indicated below:

28.4.1 TYPE TESTS

The following shall constitute type tests: -

Sl. No.

Tests For requirement Ref. To For test method Ref. to Part No. of IS:10810

(A) TEST ON CONDUCTOR i Tensile Test IS:8130-1984 2 ii Wrapping Test IS:8130-1984 3 iii Conductor Resistance IS:8130-1984 5 (B) TEST FOR OVERALL DIMENSIONS AND Clause 10, 13,14 Table- 6



Sl. No.

Tests For requirement Ref. To For test method Ref. to Part No. of IS:10810

THICKNESS OF INSULATION & SHEATH 5 of IS:694-1990 (C) PHYSICAL TEST FOR INSULATION AND

OUTER SHEATH

i Tensile Strength and elongation at break IS:5831-1984 7 ii Ageing in Air oven -do- 11 iii Shrinkage Test -do- 12 iv Hot deformation -do- 15 v Loss of mass test -do- 10 vi Heat shock Test -do- 14 vii Test for bleeding and blooming pigments -do- 19 (D) INSULATION RESISTANCE TEST IS:5831-1984 43 (E) High Voltage Test (Water immersion test) Clause 16.2 of IS:694 45 (F) Flammability test Clause 16.5 of IS:694 53

Manufacture/Bidder/manufacturer shall furnish the Type test certificate from the NABL accredited Laboratory. 28.5.1 Acceptance Tests:

The following shall constitute acceptance tests:- a.) Tensile Test (for aluminum) b.) Wrapping Test (for aluminum) c.) Conductor resistance test d.) Test for thickness of insulation and sheath e.) Tensile strength & elongation at break of insulation and sheath. f.) Insulation resistance test g.) High voltage test at Room temperature h.) Flammability test The Employer’s representative will carry out all the above acceptance tests at the time of material inspection, as per relevant ISS, for the purpose of clearing the lot offered by the Bidder. Acceptance test shall be carried out in each type and size of cable, on cable drum selected at random as per following sampling plan:-

No. of drums/ coils/Reels in the lot

No. of drums/coils/Reels to be taken as sample

Permissible number of defectives

Up to 25 3 0 26 to 50 5 0 51 to 100 8 0 101 to 300 13 1 301 & above 20 1

28.5.2 Routine Test:

The following shall constitute routine test:- a) Conductor Resistance test b) High voltage test at room temperature

c) The Bidder/manufacturer/Manufacturer, in accordance with relevant ISS,

shall conduct the above routine test and test certificate in proof of this shall be submitted to the Employer along with each inspection offer. In absence of routine test certificates, the inspection offer shall not be considered and all complication arising out of this shall be to the Bidder/manufacturer’s/Manufacturer’s account.

28.6 Inspection:

The Bidder/manufacturer/Manufacturer shall offer all reasonable facilities to the Employer, without charges, to satisfy him that the material is being supplied in accordance with the specification. In order to ensure that quality of raw-material used during manufacturing of PVC



Cables is as per requirement of IS: 694-1990, the inspecting officer shall check quality of raw material, obtain necessary invoices in proof that raw material used is of desired quality.

The Employer has the right to have any or all types of acceptance test carried out by NABL accredited laboratory whenever there is dispute regarding the quality of supply. In case the material fails to pass the test as per specification, the lot offered for inspection shall be rejected. In addition, the testing charges along with the other charges, which were actually incurred for arranging the testing through independent agency, shall be recovered from the Bidder/manufacturer/Manufacturer.



29.0 POST INSULATOR FOR 11 KV THREE PHASE AB SWITCH: 29.1 SCOPE

The specification covers Porcelain Post Insulator shells with metallic cap and base. These shells will be used for manufacturing of 11 KV 3-phase AB Switches or in other equipment in the system.

29.2 STANDARDS

Post Insulator should conform to latest applicable Indian / IEC standards and in particular to the IS:2544 specification for Porcelain Post Insulators. Polygon or compact solids core or long rod insulator is also acceptable. Creep age distance should be adequate for highly polluted outdoor atmosphere in open execution. The porcelain used for manufacture of post insulator shall be homogeneous free from flaws or imperfections that might affect the mechanical or dielectric quality. They shall be thoroughly vitrified through and impervious to moisture. The glazing of the porcelain shall be of uniform brown color, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base of the insulator shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing shall be avoided.


The maximum temperature attained by any part of the insulator when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree centigrade above ambient temperature. The corrections proposed shall be stated in the Bid and shall be subject to approval of the Employer.

29.4 INSULATOR CHARACTERISTICS

The insulator shall have the electrical and mechanical characteristics, which are given below:-

Highest system voltage 12 KV (rms) Dry one minute power frequency withstand voltage 35 KV (rms) Wet one minute power frequency with stand voltage

35 KV (rms)

Power frequency puncture with stand voltage 1.3 times the actual dry flash over voltage of the unit

Impulse voltage withstand voltage 75 KV (peak) Visible discharge voltage 9 KV (rms)

In this standard power frequency voltages are expressed as peak values divided by ½ and impulse voltage is expressed as peak values. Withstand and flashover voltage are referred to the reference climatic conditions.

29.5 MECHANICAL CHARACERISTICS The insulators shall be suitable for the minimum failing load of 10 KN. Nature of load will be transverse.

29.6 CREEPAGE DISTANCE

The minimum creepage distance of 11 KV Post Insulators shall be 320 mm for highest system voltage of 12 KV.



29.7 PACKING

All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport.

29.8 TEST The insulator shall comply with following tests as per IS:2544 -1973. 29.9 TYPE TESTS

Type tests are normally carried-out once and unless otherwise agreed to, test certificates giving the results of type tests, made on not less than 2 post insulators and post insulators unit identical in all essential details with those to be supplied are regarded as evidence of compliance. The tests should be carried out on two samples in the order mentioned below: -

(A) TEST ON BOTH INSULATORS

8. Visual examination 9. Verification of dimensions 10. Visible discharge test 11. Impulse voltage withstand test 12. Wet power frequency voltage withstand test 13. Dry power frequency voltage withstand test 14. Temperature cyclic test

(B) TEST ON FIRST INSULATORS

5. Mechanical strength test 6. Porosity test 7. Puncture test 8. Galvanizing test

29.10 ROUTINE TESTS The following shall be carried out as routine tests: -

3. Visual examination 4. Electrical routine test

29.11 ACCEPTANCE TEST

The test samples after having withstand the routine test shall be subject to the following acceptance tests in the order indicated below: -

7. Verification of dimensions 8. Temperature cyclic test 9. Mechanical strength test 10. Puncture test 11. Porosity test 12. Galvanizing test

Tolerance in insulator dimensions shall be as per the relevant Indian Standards. The Bidder/manufacturer shall invariably enclose with offer the type test certificates and guaranteed technical particulars.

29.12 MARKING Each insulator shall be legibly and indelibly marked to show the following: -

5. Name and trade mark of the manufacturer 6. Month and year of manufacturing 7. Minimum failing load in KN 8. Country of manufacturing

The above marking on porcelain shall be engraved and shall be applied before firing.

Post insulator, without above markings shall not be accepted under any circumstances.




The Bidder shall assume full responsibility for co-ordination and adequate design. All materials used in the manufacturing of Insulator shall be of the appropriate class well finished and of approved design and make. All similar parts should be accurately finished and interchangeable. All ferrous parts including Bolts & Nuts etc. used on the post insulators shall be heavily hot dip galvanized. Specific attention shall be paid to tropical treatment to the entire insulator, as it will be subject to ring service, to extremely service exposure, to atmospheric moisture and to long period of high ambient temperature.

**************



30.0 11 KV AIR BREAK SWITCHES 30.1 SCOPE

This specification provides for manufacture, testing at works and supply of 11KV AB switches. The 11KV AB switches shall conform to IS:9920 (Part-I to IV)

30.2 AB SWITCHES

The 11KV Air Break Switches are required with two poles in each phase. The AB Switches shall be supplied complete with phase coupling shaft, operating rod and operating handle. It shall be manually gang operated and vertically break and horizontal mounting type. The equipment offered by the bidder shall be designed for a normal current rating of 400 Amps and for continuous service at the system voltage specified as under:

i) 11 KV AB Switch: 11KV + 10% continuous 50 C/s solidly grounded

earthed neutral system

The length of break in the air shall not be less than 400 mm for 11KV AB Switches. The 11KV AB Switches are required with post insulators. The AB switches should be suitable for mounting on the structure. The phase to phase spacing shall be 750 mm.

30.3 POST INSULATORS The complete set of three phase AB Switches shall have stacks of post insulators. 11KV AB Switches : 1 No. 11KV Post Insulator per stack

The post insulators should conform to the latest applicable Indian standards IS:2544 Specification for Porcelain Post insulator of compact solid core or long rod insulators is also acceptable. Creepage distance should be adequate for highly polluted outdoor atmosphere in open atmosphere. The porcelain used for manufacture of AB Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown in color, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loose the parts or create undue internal stresses which may affect the electrical or mechanical strength. Cap and base of the insulators shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing must be avoided. Each 11KV Post Insulators should have technical particulars as detailed below:

S n Particulars Values i Nominal system voltage kV (rms) 11 ii Highest system voltage kV (rms.) 12 iii Dry Power Frequency one kV minute withstand voltage (rms) in KV 35 iv Wet Power frequency one minute withstand voltage (rms) in KV 35 v Power Frequency puncture kV (rms) voltage 1.3 times the

actual dry flashover voltage

vi Impulse withstand voltage kV (Peak) 75 vii Visible discharge voltage kV (rms) 9 viii Creepage distance in mm (minimum) 320

The rated insulation level of the AB Switches shall not be lower than the values specified below:-




The maximum temperature attained by any part of the equipment when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree above ambient.

30.6 MAIN CONTACTS

AB Switches shall have heavy duty self-aligning type contacts made of hard drawn electrolytic copper/brass. The various parts should be accordingly finished to ensure interchangeability of similar components. The moving contacts of the switch shall be made from hard drawn electrolytic copper brass. This contact shall have dimensions to withstand safely the highest short-circuit currents and over voltage that may be encountered during service. The surface of the contact shall be rounded smooth and silver-plated. In nutshell the male and female contact assemblies shall ensure.

1. Electro-dynamic withstands ability during short circuits without any risk of repulsion of contacts. 2. Thermal withstands ability during short circuits. 3. Constant contact pressure even when the lower parts of the insulator stacks are subjected to

tensile stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature variations or strong winds.

4. Wiping action during closing and opening. 5. Fault alignment assuring closing of the switch without minute adjustments.

30.7 CONNECTORS

The connectors shall be made of hard drawn electrolytic copper or brass suitable for AAA Weasel conductor for both 11KV AB Switches. The connector should be 4 -bolt types.

30.8 OPERATING MECHANISM

All AB Switches shall have separate independent manual operation. They should be provided with ON/OFF indicators and padlocking arrangements for locking in both the end positions to avoid unintentional operation. The isolating distances should also be visible for the AB Switches.

The AB Switch will be supplied with following accessories:

Sl No

Item Size of 11KV AB Switch

i Operating Rod (GI dia) ISI mark

Length 5.0 meter 25MM

ii Phase coupling square rod (GI) ISI mark

Length 1800 mm Size 25x25 mm

iii Hot dip galvanized Operating handle (GI)

1 No.

The AB Switches shall be capable to resist any chance of opening out when in closed position. The operating Mechanism should be of robust constructions, easy to operate by single person and to be located conveniently for local operation on the line. The GI pipe shall conform to ISS:1239-1968 and ISI marked by embossing. The vertical down rod should be provided with adequate joint in the mid section to avoid bending or buckling. Additional leverage should be provided to maintain mechanical force with minimum efforts.

Sl. No

Standard declared voltage KV/RMS

Rated Voltage of the AB Switches

Standard impulse with stand voltage (positive & negative polarity kV (Peak)

One Minute power frequency withstand voltage kV (rms)

Across the Isolating distance

To earth & between poles

Across the Isolating distance

To earth & between poles

i 11KV 12KV 85KV 75KV 32KV 28KV



All iron parts should be hot dip galvanized. All brass parts should be silver-plated and all nuts and bolts should be hot dip galvanized.

30.9 ARCING HORNS

It shall be simple and replaceable type. They should be capable of interrupting line-charging current. They shall be of first make and after break type.

30.10 BUSH

The design and construction of bush shall embody all the features required to withstand climatic conditions specified so as to ensure dependable and effective operations specified even after long periods of inaction of these Air Break Switches. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication through nipples and vent.


6.10.1 All materials used in the construction of the equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. 6.10.2 Special attention shall be paid to tropical treatment to all the equipment, as it will be subjected during service to extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. All current carrying parts shall be of non-ferrous metal or alloys and shall be designed to limit sharp points/edges and similar sharp faces. 6.10.3 The Bidder/manufacturer should have the following type test certificate. The type test should be from CPRI or NABL accredited Lab:-

1. Test to prove capability of rated peak short circuit current and the rated short time current. The

rated short time current should correspond to minimum of 10K Amp and the peak short circuit current should correspond to minimum of 25K Amps.

2. Lightning impulse voltage test with positive & negative polarity. 3. Power Frequency voltage dry test and wet test 4. Temperature rise test 5. Mill volt drop tests

6.10.4 The above tests should be performed on the AB Switches, manufactured as per owner approved drawing with the specification. Along with the type test certificate, the certified copy of the drawing (from the testing lab) should also be kept for inspection of our officer. Also the test certificates should not be older than 5 years from the date of opening of Bid. Dimension of 11 AB Switches in (Max.) Tolerance 5%.

Sl. Particulars 11KV AB Switch i MS Channel 450x75x40 ii Creepage

distance of Post Insulator

320mm (Min)

iii Highest of Port shell

254 mm

iv

i) Base 165x36x8 Ii) Contact 70x30x6 Iii) GI cover 110x44 v) Spring 6 Nos.

Moving Contact Assembly

i Base Assembly 135x25x8 ii Moving 180x25x9 iii Bush Bronze Metal



iv Thickness of Grooves 7 Connectors

i Connector 60x50x8 (Moving & fix both)

6.10.5 The bidder should provide AB Switches with terminal connectors, set of insulators, mechanical inter works and arcing horns sets. The base channel for the mounting of AB Switches shall also be included in the scope of AB Switches. The operating mechanisms together with down pipe operating handle etc. are also included in the scope of supply.

GTP OF 11 KV A.B. SWITCHES

No Particulars Requirement To be categorically specified

1 Type, make & country of origin 2 Maximum permission continuous service voltage

(KV) 12 KV

3 Length of the Break/Phase (Min.) 400 mm 4 Phase to Phase Spacing 750 mm 5 Power Frequency withstand test voltage for

completely assembled switches

A) Against ground i Dry KV 28 KV ii Wet KV 28 KV B) Across open contact i Dry KV 32 KV ii Wet KV 32 KV C) Between Phases i Dry KV 28 KV ii Wet KV 28 KV 6 Impulse withstand test voltage of completely

assembled switch without arcing horns with 1.2/50 micro second impulse wave KV (Peak)

85 KV

7 100% impulse flashover voltage of completely assembled switch with arcing horns with 1.2/50 micro second impulse wave KV (Peak)

85 KV

8 Particulars of the main contacts i.e. fixed contacts and moving contacts

a Type Spring loaded fixed & knife type moving contacts

b Material Hard drawn electrolytic copper alloy

c Surface Treatment & Thickness of Silver Coating Silver plated of thickness of 5 micron

d Contact Pressure 25 KG 9 Continuous Current Rating, Amps 400 amps 10 Short Time Current Rating KA (rms) min. for 1 sec 16 KA 11 Rated Peak Short Circuit Current (KA Peak) 25 KA 12 No. of operations which the switch can withstand

without deterioration of contacts 2000

13 Type of Mounting Horizontal up right mounting 14 Type & Material used in connector Brass/ Bronze strips 15 Location and Type of Bushing Bush bearing at rotating

insulator

16 Particulars of Post Insulators i Make( ISI make) To be indicated ii Type 11 KV Post insulator type iii Strength 10 KN iv Weight 5 Kg (approx.) / unit v No. of units per stack One vi Height of stack mm 254 mm



No Particulars Requirement To be categorically specified

viii Creepage distance mm 320 mm ix One Minute Power Frequency Dry withstand voltage

KV (rms) 65 KV

x Power Frequency Flashover voltage KV (rms) 70 KV xi Impulse flashover voltage KV (Peak) 85 KV xii Impulse withstand voltage KV (Peak) 80 KV (peak) xiii Puncture voltage (KV) 105 KV



31.0 GUY STRAIN INSULATOR 31.1 APPLICABLE STANDARDS: Except when they conflict with the specific requirements of this

specification, the insulators shall comply with IS: 5300–1969 or the latest version thereof.

31.2 GENERAL REQUIREMENTS: The porcelain insulator shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The design of the insulator shall be such that the stresses due to expansion and contraction in any part of the insulator shall not lead to its deterioration. The glaze, unless otherwise specified, shall be brown in color. The glaze shall cover the entire porcelain surface parts except those areas that serve as supports during firing.

31.3 TYPE OF INSULATORS: The standard guy system insulators shall be of designations ‘A’ and

‘C’ as per IS:5300. The recommended type of guy strain insulators for use on guy wires of overhead lines of different voltage levels are as follows:

Power line voltage Designation of insulators 11000 V C

31.4 DIMENSIONS: The dimensions of guy strain insulators shall be in accordance with REC

specifications. 31.5 BASIC INSULATION LEVELS: The test voltage of the insulators shall be as under:

Designation of Insulator

Dry one-minute power frequency withstand voltage

Wet one-minute power frequency withstand voltage

KV (rms) KV (rms) A 18 8 C 27 13

31.6 MECHANICAL STRENGTH: The insulators shall be suitable for the minimum failing loads

specified as under: Designation of Insulator Minimum failing load (KN) A 44 C 88 31.7 TESTS: The insulators shall comply with the following routine, type and acceptance test as per

IS:5300.

• Routine Test: • Visual examination • type Test • Visual examination • Verification of dimensions • Temperature cycle test • Dry one-minute power-frequency voltage withstand test • Wet one-minute power-frequency voltage withstand test • Mechanical strength test • Porosity test

Acceptance Tests: (to be conducted in the following order) • Verification of dimensions • Temperature cycle test • Mechanical strength test • Porosity test

31.8 MARKING: Each insulator shall be legibly and indelibly marked to show the following: • Name of trade mark of the manufacturer • Year of manufacturer • ISI certificate mark, if any. • Marking on porcelain shall be applied before firing.

31.9 PACKING: All insulators shall be packed in wooden crates suitable for easy but rough handling

and acceptable for rail transport. Wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.



Sl. No. 32 (Number Plate is deleted)



33.0 PORCELAIN FUSE UNITS: 33.1 Scope: This specification provides for manufacturing of rewireable type Porcelain fuses without

sheet metal cover consisting of fuse carriers and fuse bases as mentioned in Schedule – I.

33.2 Technical Particulars: (i) The porcelain rewireable type electric fuses having fuse carriers and fuse bases

of specified ratings must conform to IS:2086-1993 or with latest amendments. (ii) The material to be used for various current carrying/non-ferrous parts shall be as

tabulated below:-

S.No. Particulars Ratings 16 Amp 415 Volt 1. Terminal Block Tin plated cast brass metal

2. ‘U’ Contact Tin plated Brass/Copper strips 3. Extension strips for fixing

lugs Not to be provided

4. Side leaves Tin plated Phosphor bronze.

33.3 Iron and steel shall not be used for current carrying part including screws provided in base terminal block.

33.4 The insulating resin used to protect accidental contact of screws should be of good quality so

that it should not melt off at full load.

33.5 The screws used on terminal block for fixing of incoming and outgoing wires to the terminal should be of brass and of adequate dimension.

33.6 The dimensions of terminal holes of the fuse units must be adequate for the suitable cable

entry as under:-

For fuse units of 16 Amp rating the terminal hole should be suitable for 6 sq. mm aluminum cables.

33.7 Asbestos sheet (and not asbestos cloth) shall be used in porcelain fuse units to avoid short

circuit between earth and fuse wire. Where fuse wire is made to pass through the hole provided in the porcelain carrier, an asbestos tube must be inserted in the hole to avoid direct heating of the porcelain.

33.8 The contacts used shall be of excellent quality and alignment should be perfect so as to

provide easy but perfect contact. ‘U’ contact should penetrate full depth of based contacts. The dimension of ‘U’ contacts and terminal block used in,16 amps ratings should be as under:

S.N Ratings ‘U’Contact Dimension (mm)

Length Width Thick Terminal block dimension (mm) Height Width Length Dia. hole

1. 16 Amp/ 415V

20+1 8+.5 1+.5 10+.5 17+.5 12+.5 4.5+.5

33.9 The minimum weight of current carrying parts shall not be less than as indicated below:-

16 A /415 V - 18. Gm 33.10 The side leaves on the base should be sufficiently thick and stiff to ensure tight fittings of ‘U’

contacts with base block.

33.11 Care has to be taken to ensure that no corrosion takes place between aluminum and copper/brass of the fuse terminal being of different types of materials.

33.12 The guaranteed technical particulars should be strictly as per schedule-III enclosed.

33.13 The P.F. units should be supplied complete with all accessories, which might have not indicated

but form an integral part of the PF units.



33.14 The following embossing should be done on either side of base of P.F. units:

a) Name of the manufacturer b) MPPVVKCL logo

33.15 Acceptance Test: 33.16 The following acceptance tests should be performed on each lot (rating-wise) offered for

inspection:-

a) Visual Examination b) Test for dimensions c) Test for mechanical endurance d) Test for withdrawal force e) Test for temp. rise f) Insulation resistance test g) High voltage test h) Test on ceramics material.

i) Temp. cycle test ii) Water absorption test.

S No Particulars 16 Amp 415 V

1

Temperature rise of fuse carrier as per IS.2086

12 C

2 Temperature rise of base as per IS 2086 10 C 3 Insulation resistance

i) Between live terminal & exposed metal part ii) Between incoming live terminal & outgoing live terminal

Above 10 Mohm Above 10 Mohm

4 Size of fixing screws provided for fixing fuse 3x6 5 Thickness and width of ‘U’ contact and metal

used in ‘U’ contact 1x8 brass

6 Dimension of screws provided on terminal block for fixing the fuse wire made of brass

3x8

7 Thickness and width of base leaves and metal used for base leaves

24 swg. brass

8 Length, width and depth of base terminal block

7x10x12

9 Minimum weight of current carrying parts 18 gm



34.0 L.T. SHACKLE INSULATORS (Size 90 x 75 mm)

34.1 SCOPE: This specification cover the details of the porcelain insulators for use of 415/240 V overhead power line within electric distribution system. 34.2 STANDARDS: Unless otherwise modified in this specification, the insulator shall comply with IS: 1445-1977 with or the latest version thereof. 34.3 GENERAL REQUIREMENTS: The porcelain shackle be sound free from the defects, thoroughly vitrified and smoothly white glazed. 34.4 WHITE GLAZED PORCELAIN SHACKLE INSULATORS. White glazed Porcelain Shackle Insulators without hard ware fittings suitable for low tension 660 Volts grade overhead power lines. The insulators should of size 90x75 mm with a central hole of minimum 15 mm dia and shall conform to Shackle insulator type I of IS:1445-1977. 34.5 DRAWING AND DIMENSIONS: As per enclosed Technical Specification. Permissible tolerances in sizes are as under (All dimensions are in mm)

S.No. Particulars of Drawing

Size specified Permissible tolerance Net permissible size Plus (+) Minus (-) Maximum Minimum

1 A 90 5.1 5.1 95.1 84.9 2 B 75 4.5 4.5 79.5 70.5 3 C 85 4.9 4.9 89.9 80.1 4 D 50 3.5 3.5 53.5 46.5 5 E 40 3.1 3.1 43.,1 36.9 6 F 15 2.1 2.1 17.1 12.9 7. G 10 1.9 Zero 11.9 10.0 34.6 TEST CERTIFICATE: The Bidder/manufacturer/Manufacturer shall be required to furnish with their offer, test certificate from NABL Accredited laboratory giving results of following test as per IS:1445-1977 with latest amendments:-

(i) Visual examination (ii) Verification of Dimensions. (iii) Dry power frequency voltage withstand test. (iv) Wet power frequency voltage withstand test. (v) Temperature cycle test. (vi) Mechanical failing load test. (vii) Power frequency puncture withstand test. (viii) Porosity test.

Acceptance Tests & routine tests shall be as per ISS:1445-1977 with latest amendment. 34.7 INSPECTION: 34.7.1 The Employer’s representative shall at all times be entitled to have access to the works and all places of manufacture where equipment/material shall be manufactured and the representative shall have full facilities for unrestricted inspection of the Bidder/manufacturer’s works raw materials and process of manufacture for conducting necessary tests as detailed herein.



34.7.2 The Bidder/manufacturer/Manufacturer shall keep the Employer informed in advance of the time of starting and of the progress of manufacture of equipment/material in its various stages so that arrangements can be made for inspection. 34.7.3 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off by the Employer in writing. In the later case also, the equipment/material shall be dispatched only after satisfactory testing for all tests specified herein has been completed. 34.7.4 The acceptance of any quantity of material shall in no way relieve the Bidder/manufacturer of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is alter found to be defective. 34.7.5 The number of sample selected to carry out the acceptance test shall be as per provision in the respective IS. 34.7.6 The Employer has the right to have the tests carried out by NABL accredited laboratory or an independent Agency subject to recovery of testing expenditure in case of failure, whenever there is dispute regarding the quality of supply. 34.8 The successful Bidder/manufacturer/Manufacturer shall within 30 days of placement of order submit following information to the Employer.

(i) List of raw material as well as bought out item accessories and the names of sub-Bidder/manufacturers selected form those furnished along with offer.

(ii) Type test certificate of raw material and bought out accessories, if any. (iii) Quality assurance plan (QAP) with hold points for the Employer’s inspection.

The quality assurance of plan and Employer’s hold points shall be discussed between the Employer and Bidder/manufacturer, before AQP is finalized.

34.9 DOCUMENTATION: The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the Employer. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at Bidder/manufacturer’s risk. 34.10 PACKING AND FORWARDING: 34.10.1 The equipment shall be packed in cerates suitable for vertical/horizontal transport, as the case may be and suitable to withstand handling during transport and outdoor storage during transit. The Bidder/manufacturer/Manufacturer shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbols. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc. shall be provided. Any material found short inside the packing cases shall be supplied by Bidder/manufacturer without any extra cost. 34.10.2 MARKING: Each consignment shall be accompanied by a detailed packing list containing the following information: (a) Name of consignee. (b) Details of consignment. (c) Destination. (d) Total weight of consignment. (e) Handling and unpacking instructions. (f) Bill of material indicating contents of each package.

34.10.3 On each packages/crates containing the material/equipment following information shall be distinctly on it in indelible ink along with other essential data. (i) Contact Award letter number



(ii) Name and address of consignee (iii) Manufacturer’s name and address (iv) Name of item (v) Quantity (vi) Gross weight (vii) Arrow marking for stacking/opening

Guaranteed Technical Particulars for LT shackle Insulators

S. No Particulars Required Offer by the bidder

1 Standard specification to which the insulator shall conform

IS:1445/1977 with latest amendments

2 Dimensions 90x75 mm 3 Hole diameter 15 mm 4 Tolerance in various

dimensions (in mm) (+) (0.04d+1) mm (where d = dimensions)

5 Colour White glazed 6 Dry flashover voltage As per IS

specification

7 Wet flashover voltage As per IS specification

8 Dry one minute power frequency withstand voltage

23 KV (rms.)

9 Wet one minute power frequency withstand voltage

10 KV (rms.)

10 Power frequency puncture withstand voltage

1.3 X the actual Dry flashover voltage

11 Minimum Mechanical failing load

11.5 KN



35.0 TECHNICAL SPECIFICATION FOR `ISI' MARKED XLPE INSULATED AND PVC SHEATH 1100 VOLTS AERIAL BUNCHED CABLE

35.1. SCOPE: The specification covers the design, manufacture, testing and delivery at places anywhere in MP for the following cables suitable for LT overhead lines:- 1100 Volts ISI marked Aluminum Conductor XLPE Insulated & PVC sheathed Aerial Bunched cable conforming to IS:14255/ 1995 with latest amendment and as per technical specification of following sizes i) 3x50 Sq.mm+1x16 sq.mm. with 1x35 Sq.mm bare Al.Alloy Messenger wire. ii) 3x25 Sq.mm+1x16 sq.mm. with 1x25 Sq.mm bare Al.Alloy Messenger wire iii) 3x16 Sq.mm+1x16 sq.mm. with 1x25 Sq.mm bare Al.Alloy Messenger wire iv) 3x16 Sq.mm with 1x25 Sq.mm bare Al.Alloy Messenger wire 35.2. RATED VOLTAGE: The rated voltage of the cables shall be 1100 volts 35.3. APPLICABLE STANDARDS: Unless otherwise stipulated in this specification the following standards shall be applicable.

(i) IS – 14255/1995: AB cables up to 1100 volts. (ii) IS – 8130/1984: Conductors for insulated cables. (iii) IS – 398/Pt.IV/1994: Aluminum alloy conductor. (iv) IS – 10418/1982: Drums for electric cables

35.4. GENERAL: The cable covered under this specification should be suitable for use on three phase, 4 wire earthed system for working voltage up to 1100 V. It should conform to the relevant standards stated above and others if applicable. The phase conductors shall be 50/25/16 mm² XLPE, insulated street light conductor 16 mm² XLPE insulated and both shall be PVC sheathed and the messenger conductor shall be 35/25 mm² bare heat treated silicon containing 0.5% magnesium and approximately 0.5% silicon confirming to IS: 398 (Part-IV):1979 and its latest amendment, if any. 35.5. PHASE & NEUTRAL CONDUCTORS: 35.5.1 The phase and street light conductors shall be provided cross linked poly ethylene insulation applied by extrusion. The thickness of insulation shall not be less than 1.2 mm up to 35 mm2 and shall not less than 1.5 mm for above 35mm2 at any point and insulation shall be so applied that it fits closely on the conductor and it shall be possible to remove it without damaging the conductor. In addition to XLPE insulation each XLPE insulated core shall have BLACK PVC coating over XLPE insulation having thickness of 1 mm and identification of core shall be on coating. The insulated conductors shall generally conform to the standards IS-14255:1995. 35.5.2 The phase conductors shall be provided with one, two & three ‘ridges’ for easy identification. 35.5.3 The tensile strength of the aluminum wire used in the conductor shall not be less 90 N/mn². 35.5.4 The standard size and technical characteristics of the phase conductors shall be as shown in the Table-1.

TABLE-I Nominal sectional area in mm²

No. of Strands

Diameter of

compacted

condu

Approx. mass

Kg/Kms.

Max. DC Résistance

at 20ºc (Ohm/km)

Insulation Thickness

In mm



ctor in mm.

16 7 4.4 42 1.91 1.2 25 7 5.5 65 1.20 1.0 35 7 6.8 95 0.868 1.0 50 7 7.9 127 0.641 1.5

NOTE: 1) The resistance values given above are the max. permissible. 2) Tolerance of + 5% is allowable on dimension.

35.6. MESSENGER WIRE:

35.6.1 The bare messenger wire shall be of Aluminum alloy generally confirming to IS–398/Pt.IV/94 composed of 7 strands and shall be suitable compacted to have smooth round surface to avoid damages to the overall insulation of phase & neutral conductor twisted around the messenger. 35.6.2 There shall be no joint in any wire of the stranded messenger conductor except those made in the base rod or wires before final drawing. 35.6.3 The sizes and other technical characteristics of the messenger wire shall be as given in the Table No.2.

TABLE –2 Nominal sectional area in mm²

No. of Strands

Diameter of

compacted conductor

in mm.

Approx. mass

Kg/Kms.

Max. DC Résistance

at 20ºc (Ohm/km)

Minimum Tens

ile Strength (KN)

25 7 5.5 65 1.380 7.4 35 7 6.8 95 0.986 10.30

NOTE: 1) The resistance values given above are the max. permissible. 2) Tolerance of + 5% is allowable on dimension.

35.7. XLPE INSULATION: The insulation shall generally conform to IS-7098(Part-I):85

35.8. TYPE TEST:

Property Requirement

Tensile Strength 12.5 N / mm² Min Elongation at break 200 % Min Ageing in air over a. Treatment: temperature & duration 135°C ± & 7 days Tensile strength variation+ +25% Max. Elongation variation + 25% Max

4a Treatment temperature Time under load mechanical stresses

200°C 15 minutes 20 N /cm².

Elongation under load 17.5 % max Treatment temperature & duration 130°C for 1 hours Shrinkage 4% max Water absorption (Gravimetric) Treatment – Temp. Duration 85 + 2°C 14 days Water absorbed 1 mg. / cm² max



(A) Test for Phase/Street Light Conductors a) Tensile Test (IS-8130) b) Wrapping Test (IS-8130) c) Conductor Resistance Test (IS-8130)

(B) Test for Messenger: a) Breaking load test (to be made on finished conductor) –(IS-398 / Pt.IV / 1994 with

latest revision) b) Elongation test (IS - 398 / Pt.IV/1994) c) Resistance test (IS - 398 / Pt. IV /1994)

(C) Physical test for XLPE insulation

i) Tensile strength and Elongation at break ii) Ageing in air oven iii) Hot set test iv) Shrinkage test v) Water absorption (Gravimatric) vi) Carbon black

1. Content & 2. Dispersion (D) Test for thickness of insulation (E) Insulation Resistance (Volume Resistivity) Test (F) High Voltage Test (G) Bending test on complete cable:

Bending test shall be performed on a sample of complete cable. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. It shall then be unwound and the process shall be repeated after turning the sample around its axis 180. The cycle of this operation shall be then repeated twice.

The diameter of mandrel shall be 10 (D+d).

Where D = Actual diameter of cable (i.e. the min. cir scrutiny circle diameter)

d = Actual diameter of the conductor in mm No. cracks visible to the naked eye are allowed. The Bidders should submit all the above type test within 28 days of the Letter of Award.

35.9. ACCEPTANCE TESTS: 35.9.1 Tests for Phase / Street Light Conductors :

a. Tensile test (for Phase / Street light conductor) b. Wrapping test (for Phase / Street light conductor) c. Breaking load test for messenger conductor d. Elongation test for messenger conductor e. Conductor Resistance test f. Test for thickness of insulation g. Tensile strength and elongation at break test h. Hot set test ( For XLPE insulation) i. Insulation Resistance test j. High voltage test

35.9.2 Bending Test on complete cable: Bending test shall be performed on a sample of complete cable as under.

The sample shall be wound around a test mandrel at room temperature for at least one complete turn. It shall be than unwound and the process shall be repeated after turning the sample around its Axis 180°. The cycle of these operation shall than be repeated twice. The dia of the mandrel shall be 10 (D+d).

Where D = Actual diameter of cable d = Actual diameter of the conductor in mm

No cracks visible to the naked eye shall be permitted.



35.10. PACKING MARKING: 35.10.1 The cable shall be wound in non returnable drums conforming to IS-10418/1982 “Specification for Reels and Drums for bare wire” of the latest version thereof. The drums shall be marked with the following:

a) Manufacturers name b) Trade mark, if any c) Drum number d) Size of Conductor e) Size of Messenger f) Voltage grade g) Number of lengths of pieces of Cable in each drum h) Gross mass of the packing i) Net mass of Cable j) ISI mark.

35.10.2 The drums shall be of such a construction as to assure delivery of conductor in field free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that cable surface not dented, scratched or damaged in any way during transport and erection. The cable shall be properly lugged on the drums. 35.10.3 The cable drums should be suitable for wheel mounting. 35.11. STANDARD LENGTH: The standard length of drum will be 500 metre with ± 5% Non-standard Length: Non standard length not less than 50% of the standard length shall be accepted to the extent of 10% of the ordered quantity. 35.12. INSPECTION:

All tests and inspections shall be made at the place of manufacturer unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 35.14. TYPE TEST CERTIFICATES:

The bidders have to submit valid type test certificate as per IS(14255), regarding climate aging Test (NFC 20-540), Corrosion Test (NFC 33-003)and UV resistant certificates not before last 5 years, from any NABL accredited or Govt. lab along with their offer for the offered or higher size of AB Cable.



GUARANTEED TECHNICAL PARTICULARS OF CABLE

Bidders have to confirm following important requirements separately for each size: i) 3x50 Sq.mm+1x16 sq.mm. with 1x35 Sq.mm bare Al.Alloy Messenger wire. ii) 3x25 Sq.mm+1x16 sq.mm. with 1x25 Sq.mm bare Al.Alloy Messenger wire iii) 3x16 Sq.mm+1x16 sq.mm. with 1x25 Sq.mm bare Al.Alloy Messenger wire iv) 3x16 Sq.mm with 1x25 Sq.mm bare Al. Alloy Messenger wire

Sno. Particulars Size of Cables 1 Cable shall be manufactured and supplied

conforming to IS: 14255/1995 with latest amendment if any

2 Cable drums/label shall bear ISI Mark 3 ISI License shall remain valid till order is

Completed

4 Colour of XLPE Insulation – Black 5 Shape – compacted 6 Standard length in case of drum of 500 metres ± 5

%

7 Non-Standard length 50% of Std. length up to 10% of ordered qty.

8 Packing shall contain only one Length 9 Packing material Wooden drums as per IS:10418/

1982 duly painted

10 Following shall be embossed on cable a. MPEZ b. 1100Volts c. IS: 14255/1995 d. Year of manufacture e. Trade Mark

Marking on drum shall be as per IS:14255/1995

11 Conductor (i) For Phase a) Material (Grade) b) 50 & 16 Sq.mm. Alluminium as per IS 8130/1984

(ii) For Messanger wire a) Material (Grade) b) 35 sq.mm Alluminium Alloy as per IS 398/

Pt.IV/1994

12 Maximum phase Conductor resistance at 20ºC a.50 sq.mm Conductor – 0.641 Ohm/Km b.16 sq.mm Conductor – 1.91 Ohm/Km

13 Maximum Messenger Conductor resistance 35 sq.mm. at 20ºC

14 Thickness of insulation (min in mm) 15 Volume resistivity of insulation

at 27°C at 70°C

16 a. Tensile strength of Insulation (Min) b. Elongation at break of Insulation

17 a. Thickness of sheath in mm(min) b. Tensile Strength (Min) c. Elongation % d. Cold Bend e. Cold impact

18 Overall Tolerance in supply of ordered total quantity

shall be ±2 %

19 Approx weight of complete cable per Km



36.0 TECHNICAL SPECIFICATION FOR ACESSORIES (CLAMPS), DISTRIBUTION BOX etc. SUITABLE FOR AERIAL BUNCHED CABLE

36.1 SCOPE : This specification covers manufacturing, testing before dispatch, of hardware/ accessories suitable for LT Aerial Bunched XLPE insulated PVC sheathed phase conductor (Aluminum) cables with bare messenger wire for LT overhead lines suitable for working voltage up to & including 1100 Volts as per relevant REC construction standards. The hardware /accessories will be supplied with Suspension Clamps and Eye Hook with PCC/ Girder Pole Clamps, Dead End Clamp / Anchoring Clamp and Eye Hook with PCC/ Girder Pole Clamp, Insulation Piercing Connectors along with Nuts, Bolts, and Washers.

36.2 APPLICABLE STANDARDS Unless otherwise stipulated in this specification the following standards with latest amendments shall be applicable: SUSPENSION CLAMP ASSEMBLY:

a) The suspension clamp shall conform to NFC 33-040 standard. b) The suspension clamp shall provide sufficient flexibility to allow for movement of

clamp at both straight run and angle locations. c) The suspension clamp shall be capable of holding bare Al. Alloy messenger wire size

of 50/ 35 /25 sq.mm. d) The suspension clamp shall have good finish and shall be free from all flaws, sharp

radius of curvature and edges shall be suitably rounded off. e) The design of clamp shall be bolt-less, neutral messenger should be fixed by an

adjustable grip device. There should not be any loos-able part in the process of clamping.

f) The Suspension clamp shall be made fully of insulating type of mechanically strong and weather resistant plastic for protection of phase cable.

g) The suspension clamp shall be provided with suitable Eye Hook & Pole Clamp to erect them on 8M PCC / Girder Poles having top and bottom dimensions as per NFC 33-040 standard. However, the size and no. of pole clamps should be got confirmed invariably before supply.

h) The performance/ test requirements shall be as per NFC 33-040 standards.’

‘ANCHORING CLAMP/ DEAD END CLAMP ASSEMBLY:

(a) The anchoring clamp/ dead end assembly shall conform to NFC 33-041 standards. (b) The anchoring clamp (dead end assembly) shall be capable of holding bare Al. Alloy

messenger wire size of 25sq.mm, 35sq.mm and 50sq.mm respectively. (c) The anchoring clamp/ dead end assembly shall have good finish and shall be free

from all flaws, sharp radius of curvature and edges shall be suitably rounded off. (d) The design of clamp shall be boltless i.e. no tools required to clamp the messenger

wire. Wedge type clamps shall be used for clamping the messenger without damaging the strands of the bare messenger. The clamp shall be of aluminium body with fully insulating type of mechanical and weather resisting thermoplastic wedges.

(e) The Anchoring Clamp shall be supplied with a stainless steel flexible Rope to connect the Tension Clamp to the Eye Hook. The flexible Rope forming part of clamp should be of length to maintain at least 150mm distance between Eye Hook and body of clamp. The rope should have sufficient flexibility to ease the torsional movement of the ABC system

(f) The anchoring clamp/ dead end assembly shall be provided with suitable Eye Hook & Pole Clamp to erect them on 8M PCC/ Girder Poles having top and bottom dimensions as per NFC 33-041 standards. However, the size and no. of pole clamps should be confirmed invariably before supply.

(g) The performance/ test requirements shall be as per NFC 33-041 standards.’

36.3 GENERAL REQUIREMENTS: The hardware/accessories should be suitable for AB Conductor required as under: The phase conductors shall be 50mm2/35mm2/25mm2 and street light conductor 16mm2 XLPE insulated PVC sheathed (1mm) and neutral cum messenger conductor shall be 35mm2 /25mm2 bare heat treated Aluminum silicon containing 0.5% magnesium and approximately 0.5% silicon conforming to IS:398 (Part-IV) 1979 and its latest amendment, if any.



36.4 SUSPENSION CLAMP ASSEMBLY: a) The suspension clamp shall conform to relevant REC construction standards. b) The suspension clamp shall provide sufficient flexibility to allow for the movement of clamp

at both straight run and angle locations. c) The suspension clamp shall be capable of holding bare Al. Alloy messenger wire size of 35 /

25 sq.mm. d) The suspension clamp shall have good finish and shall be free from all flaws, sharp radius

of curvature and edges shall be suitably rounded off. e) The suspension clamp shall be provided with suitable Eye Hook & Pole Clamp to erect

them on 8M PCC / Girder Poles having top and bottom dimensions as per standard REC specifications. However, the size and no. of pole clamps should be got confirmed invariably before supply.

f) The performance/ test requirements shall be as per REC construction standards 36.5 ANCHORING CLAMP/ DEAD END CLAMP ASSEMBLY:

a) The anchoring clamp/ dead end assembly shall conform to REC construction standards. b) The anchoring clamp (dead end assembly) shall be capable of holding bare Al. Alloy

messenger wire size of 25 sq.mm and 35 sq.mm respectively. c) The anchoring clamp/ dead end assembly shall have good finish and shall be free from all

flaws, sharp radius of curvature and edges shall be suitably rounded off. d) The anchoring clamp/ dead end assembly shall be provided with suitable Eye Hook & Pole

Clamp to erect them on 8M PSC/ Girder Poles having top and bottom dimensions as per standard REC specifications. However, the size and no. of pole clamps should be confirmed invariably before supply.

e) The performance/ test requirements shall be as per REC construction standards.

36.6 INSULATION PIERCING CONNECTORS: a) The L.T. Insulating Piercing Connectors are used for making Tee or Tap off connections to

an Aerial Bunched Cables suitable upto 1.1 KV, service voltage 0.6 KV. b) The L.T. Insulation Piercing Connectors shall conform to NFC-33-020. c) The L.T. Insulation Piercing Connectors shall be following type:

----------------------------------------------------------------------------------------------- Type Main Cable Tap Off Cable End Cap suitable for Sealing Branch --------------------------------------------------------------------------------------------- I 16-50 Sq.mm. 16-50 Sq.mm. 16-50 Sq.mm. XLPE or PVC XLPE or PVC

II 16-50 Sq.mm. 1.5-10 Sq.mm. 1.5-10 Sq.mm. XLPE or PVC XLPE or PVC

---------------------------------------------------------------------------------------------- d) The L.T. Insulation Piercing Connectors are designed to make a connection between the

uncut main conductor & a branch cable conductor without removing the insulation and with single tightening. The IPC will first pierce the insulation, and then make good electrical contact between the main & the branch conductor while simultaneously insulating & sealing the connection. The piercing teeth shall be made of Copper Alloy.

e) The Insulation Piercing Connectors must be suitable for application by one worker working alone with a 17mm/ 13mm/ 10mm wrench.

f) The Insulation Piercing Connectors must be equipped with Aluminum alloy shear heads with minimum & maximum torque as indicated by the manufacturer and within the range specified in NFC 33-020.

g) The Insulation Piercing Connectors shall be water proof & the water tightness shall be ensured by appropriate elastomer material

h) The Connector shall have removable end cap for sealing cut end of the branch cable enabling tapping on either side of the connector with the connector being in its vertical position with bolt head upward. The End cap shall be rigid of slide type enabling easy positioning and unloosable after the tap cable is positioned. The End cap shall be equipped with a water tightness seal.

i) Rubber seal around piercing teeth shall be compatible with grease used. Rubber seal shall be designed in a manner to provide proper sealing around the piercing & to avoid the damage to conductor insulation beyond piercing point. Rubber parts shall comprised of material that exhibit resistance to aging caused by heating or other weather conditions.

j) All the insulating material used shall be UV resistant & fire retardant. Metallic parts shall be non- corrosive surface treatment. Exposed metallic parts shall be potential free during & after connector mounting.



k) The Insulation Piercing Connectors shall have good finish and shall be free from all flaws, sharp radii of curvature and suitably rounded off.

l) The performance/ test requirements of insulation piercing connectors shall be as per NFC Standards 33-020.

36.7 EARTHING CONNECTOR:

Earthing connector shall be one bolt type made of Extruded Aluminum Alloy conforming to IS:617-75 and shall be suitable for 25 to 50 sq. mm. bare messenger wires. The bolt & washers shall be made of Mild Steel conforming to IS:1573 The Boltless wedge type earthing connectors conforming to REC construction standards shall also be acceptable.

GUARANTEED TECHNICAL PARTICULARS FOR (i) SUSPENSION /DEAD END CLAMP ASSEMBLY FOR BARE MESSENGER WIRE

S. N

PARTICULARS Suspension Clamp Dead end/ Anchor clamp

1. Name & Address of manufacturer

2. Standard to which material conforms 3. Are GA drawings enclosed? 4. Are experience certificate enclosed? 5. Suitable for (size of messenger)? 6. Material used in manufacture 7. Method of Manufacturing 8. Tension load 9. Test voltage (Min 6 KV AC for 1 minute) 10. Length, width & thickness of complete connector/

assembly

(ii) INSULATING PIERCING CONNECTOR FOR AERIAL BUNCHED CABLE

S. N PARTICULARS TO BE SPECIFIED 1. Name of Bidder 2. Name & Address of manufacturer of Piercing Connector 3. Are GA drawings enclosed? 4. Are experience certificate enclosed? 5. Insulation Piercing Connectors range

Main : 16 - 50 mm2, Branch (Tap off): 1.5 - 10 mm2

6. Is any metallic part carrying potential in operation exposed during installation?

7. Material used for teeth 8. Surface Finish of teeth 9. Are end caps for branch cable provided? 9.1 Slide on type 9.2 Rigid 10. Are torque limiting shear heads provided on tightening

bolts?

11. Rated tightening torque (Nm) 12. Torque for establishing connection between Main & Branch

(Nm)

13. Max. Tensile Load for no Break down of main conductor. (Kg)

14. Max. Tensile Load on Branch conductor for no slippage/break. (Kg)

15. Voltage withstand under water immersion 16. Electric aging test report enclosed? 17. No. of cycles 18. Max. Temp. in each cycle (Deg.) 19. Over current test current i. Value (Amps) Ii Duration (Sec) 20. Resistance change duration



21. Is Corrosion test report enclosed? 22. Is Climate Ageing test report enclosed?

(iii) EARTHING CONNECTOR (CLAMP FOR NEUTRAL CONNECTION)

S. N

PARTICULARS TO BE SPECIFIED

1. Name & Address of manufacturer of CLAMP FOR NEUTRAL CONNECTION

2. Are GA drawings enclosed? 3. Are experience certificate enclosed? 4. Materials 5. Conductor range (mm2) 6. a) Length, width & thickness of complete connector

b) No. of bolts along with nuts and washers

7. Particulars of Galvanisation



37.0 L.T. DISTRIBUTION BOX SPRING LOADED CONSTANT PRESSURE MULTICONNECTION TYPE FOR 3 PHASE AND SINGLE PHASE

SUPPLY

37.1 SCOPE:- This specification provides for design; manufacture, testing, supply & delivery of UV resistant Fire Retardant Polycarbonate box suitable for connection of 5 nos. single phase connections or 2 nos. three phase connections as per drawing no. Discom/EZ/43-44. The purpose of distribution box is to provide service connection from AB XLPE cable to consumer meter through service line.

37.2 Material & Construction of the enclosure – the specification is modified to read as under – The box (enclosure) shall be made of UV resistant Fire Retardant Polycarbonate or thermosetting plastic (Glass reinforced polyester Sheet Moulding Compound) SMC conforming to IS-13410:1992 capable of withstanding boiling water for 10 minutes without deformation of box material. The heat deflection temperature of the box material should be 1250C @ 0.45 mpa. The flammability rating of the material as per UL 94 should be V0. The process adopted for manufacture of these boxes should be injection/Hot press Compression moulding process.

(ii) 37.2 (b) The Dimension & General details shall be as per GTP and specs. approved by the purchaser and suitable to purchaser’s requirement.

a)The internal dimensions of the box (enclosure) for single phase 1 incoming and 5 outgoing should be :350x270x200 mm ±5%

b)The internal dimensions of the box (enclosure) for three phase 1 incoming and 2 outgoing should be: 400x300x200 mm ± 5%.

The other Dimensions & General details shall be as per Specification / GTP.

37.3 . COMPONENTS The box shall have concealed type hinges, no screws/rivets visible from outside.’ The opening

of the box cover should be from downside to upside, Lock and key arrangement with push button. Side opening of box is not acceptable.

b. Neoprene Rubber gasket to be provided all around the cover. c. Four Sets of Busbar molded casing for three phase supply and Two sets of Busbar

molded casing for single phase supply each containing two copper bus bars and spring loaded system along with pressure plates should be provided.

d. Bus bars: i). For Single Phase : The Bus bars should be made of EC grade copper and with a total cross section of 75 sq. mm approx (Two Busbars of 37.5 Sq. mm each, making a total of 75 Sq. mm). The minimum length of copper bus bars should not be less than 209 mm. The minimum current rating of Busbars should be 200 Amps.

The Busbars meeting the requirement of aforesaid current rating and maximum current

density be provided in two identical pairs for Phase as well as for neutral.

Two sets of Nylon supports are to be provided at the ends of Bus Bar casings to enable it to be fixed at Base at an easy to wire angle. The four ends of the Nylon supports shall be suitably affixed with the base of box by providing Nuts, Bolts & Washers.

ii). For Three Phase : The Bus bars should be made of EC grade copper and with a total cross section of 75 sq. mm approx (Two Busbars of 37.5 Sq. mm each, making a total of 75 Sq. mm). The minimum length of copper bus bars should not be less than 84 mm. The minimum current rating of Busbars should be 200 Amps.

The Busbars meeting the requirement of aforesaid current rating and maximum current density be provided in two identical pairs for each Phase as well as for neutral.

Two sets of Nylon supports are to be provided at the ends of Bus Bar casings to enable it to be fixed at Base at an easy to wire angle. The four ends of the Nylon supports shall be suitably affixed with the base of box by providing Nuts, Bolts & Washers.



a. The pressure plates which keep pressing the cable conductor & springs with sufficient strength of thickness 2mm. and diameter of spring wire should not be less than 2.0 mm. Both are to be made of stainless steel only. b. The springs are required to be retained in the housing by means of a stainless steel rod at the bottom end of the housing so as to exert pressure on the pressure plate when cable is inserted in the Bus Bar. The minimum spring size should be about 35 mm from end to end with a outer diameter of 14.25 mm and wire dia of 2mm. c. The Pressure Plates and Busbar System should be suitable for incoming up to 50 Sq mm Aluminum/Copper Cable and up to 35 Sq mm Aluminum/Copper Cable for outgoing circuits. d Spring loading system: The connections system shall be spring loaded so that no fasteners are required to add a new connection from the distribution system. Also, each connected cable shall have a pressure applied to it at the point of connection to provide connection integrity and eliminate loose connections. Arrangement: The busbar housings shall be arranged and mounted at a suitable stepped angle so that making new connections is easy without much bending the cables. a. In case of Single Phase : There shall be a provision of one incoming circuit of single phase & Neutral & 5 outgoing connections of single phase and neutral in the bus bars. b In case of Three Phase : There shall be a provision of one incoming + two outgoing circuits on each of three phase and neutral busbars. c. At bottom side of the enclosure, a M.S. Hot Dip Galvanised 1.2 mm sheet Gland Plate with 10 Nos. of holes is to be provided for One incoming and Nine outgoing cables for single phase and 4 Nos. of holes is to be provided for one incoming and three outgoing cables from each phase and neutral as per drawings. d One set of Mounting arrangements for fixing of box shall be supplied free of cost with each box. e. The procedure of installation with diagram shall be provided with each box kept inside. f Property of MPPKVVCL, Jabalpur should be embossed or suitable method shall be adopted on the cover of the box in big font. Note:- The first part of the designation refers to the number and size of insulated phase conductor and

the middle refer to insulated Street light conductor and last refers to the size of bare messenger/neutral wire. The sizes shown are the nominal cross sectional area of the conductors.

37.4 DRAWINGS: i. A drawing / picture clearly showing principal parts & dimensions for all products should be

submitted along with the offer. ii. The principal outer dimensions of each item, 1 x b x w in mm and weight in gms should be

submitted along with the offer. Few examples of drawings of various accessories are shown in Schedule-II(B). However bidders are advised to submit their own design/drawings of respective item duly type tested as

per relevant standards. The successful bidder within two weeks of placement of order shall furnish three sets of final versions of

all drawings of hardware/ accessories for purchaser’s approval along with sample finalized. 37.5 TESTS & TESTS CERTIFICATES:

(i) The Hardware / accessories should meet the requirement of all tests as specified in respective REC construction and NFC standard- REC E-34, E-35, IS:2629 & IS:2633, NFC-33-020, IS:617-75 and IS:1573 along with other relevant standards and their latest amendments.



(ii) The bidder shall furnish latest complete type test certificates (should not be older than 5 years) prescribed in respective REC construction and NFC standard from any NABL Accredited / CPRI, Bangalore / CPRI, Bhopal/ CPRI, Muradnagar testing laboratory or a COFRAC certified laboratory. The MPPKVVCL shall reject the offer of the bidder who does not have valid type test report.

Type test:- The following shall constitute Type tests for Suspension and Dead end Clamps

i) Tensile Test on Brackets ii) Tensile / Mechanical Test on sub-assembly iii) Slippage Test (for suspension Clamp only) iv) Voltage test on assembly v) Corrosion Test vi) Climatic Test

Endurance test under Mech and Thermal Stress (for Anchor Clamps only) Acceptance Tests:- The following shall constitute acceptance tests: For Anchor Assemblies

i) Visual * ii) Dimensional (as per SCD and Overall dimensions submitted with tender ) * iii) Mechanical Test on bracket ** iv) Mechanical test on clamp ** v) Voltage Test *

For Suspension Assemblies

vi) Visual * vii) Dimensional (as per SCD and Overall dimensions submitted with tender) * viii) Mechanical Test on Bracket ** ix) Mechanical tests on Clamp ** x) Voltage Test *

The above tests are to be carried out as per sampling plan below. In case of random failure/defect, double the sample lot is to be drawn and there should be no

failure/defect exceeding half the permissible defects (rounded down) shown in the chart.

For tests Marked * For Tests Marked ** Lot Size Sample Size Max permissible

Defects Sample Size Max permissible

Defects Upto 100 2 nil 1 Nil 101-500 5 1 2 Nil 501-2500 10 2 2 Nil 2501 & above 10 + 0.2 % 2 + 10 % of

additional sample qty

4 1

The bidder must also clearly indicate various testing facilities available at their works for testing

the material as per relevant standard. In case of other particulars of the place such testing is proposed to be conducted during the course of inspection shall be indicated with the offer.

37.6 Type test on Distribution box ‘The following tests have to be done on any one model of spring loaded constant pressure multi connection busbar in insulated box from NABL accredited laboratories only. In absence of these tests the tender will be liable for rejection. S N

Standard Clause Requirement Test Particulars

Type Routine Acceptance

1 IS:14772 7 Marking T A 2 AS per specs &

GTP - Dimensions T - A

3 IS:14772 9 Protection against electric shock

T R _

4 IS:14772 12 Resistance to aging to humid conditions, to ingress solid object & to

T - -



harmful ingress of water IP:55

5 IS:14772 13 Test for mechanical strength

T - -

6 IS:14772 14 Resistance to heat T 7 IS:14772 16 Resistance to rusting T 8 IS:14772 17 Resistance to tracking T 9 IS:14772/ IEC

695-2-1 Glow wire test at 95°C T

10 IS:8623 Verification of dielectric properties

T

11 IS:13411 Heat deflection test of 150°C at 0.45 MPa

T

12 IS:4249 3.5.1 Test for self extinguishing properties

T

13 IS:11731-II Flammability test T 14 Of/ At NABL Lab Enclosure material

identification T A

Following tests are to be conducted for bus bar

15 Temperature rise at 200 Amp

T

16 IS:2683-I Verification of electric properties of molded casing of bus bar at 2.5KV

T

17 IS:11000-I/ IEC 695-2-1

Glow wire test at 95°C of molded casing of bus bar

T

18 Of/ At NABL Lab Bus bar casing material identification

T A

37.7 INSPECTION:

(iii) The inspection may be carried out by the purchaser at any stage of manufacture.

The successful bidder shall grant free access to the purchaser’s representative at reasonable time when the work is in progress. Inspection and acceptance of any equipment / material under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment / material are found to be defective.

(iv) The acceptance tests shall be carried out as per relevant REC construction/ NFC

standards/ ISS as applicable.

(v) The supplier shall keep the purchaser inform in advance about the manufacturing program so that arrangement can be made for inspection.

(vi) The purchaser reserves the right to insist for witnessing the acceptance /routine

tests of the bought out items.

37.8 ACCEPTABILITY OF SUPPLIED MATERIAL:

One sample from the 1st Lot of Hardware of each size as received in purchaser's store shall be sealed for getting it type tested as per relevent REC construction standard /NFC Standard/ISS from any of CPRI, Bangalore/ Bhopal, CPET or any NABL accredited testing laboratory.

37.9 EMBOSSING & IDENTIFICATION:

It should be provided in each piece as per provision of bid document.



37.9 GUARANTEED TECHNICAL PARTICULARS FOR DISTRIBUTION BOX

S.

N Particulars Requirement

Offered

1. Manufacturer

Name

2 Material of Box

Enclosure

UV resistant Fire

Retardant

polycarbonate

3 Thickness 2 mm. minimum

4 Dimension of the

enclosure

offered dimensions shall

be suitable to the

requirements

5

Material of

insulation for

mounting Busbar

(Bus Bar

Supports)

Nylon Glass Filled FR

6

No. of circuits

both incoming &

outgoing in the

Busbar

Single Phase :

1 incoming + 5 outgoing

Three Phase :

1 Incoming + 2 outgoing

7

Material of

Insulation for

Busbars molded

casing

Nylon Glass filled & Fire

Retardant passing

950°C Test as per IEC

Publication 695–2–1

8 Material of Bus

Bar

EC Grade Copper,

electrical class “A”

9 Cross Section

area of Bus Bar

Total 75sq.mm (2Nos.

of 37.5Sq.m each)

10

No. of Busbar

completed with

fitting

Single phase box 2 Sets (one for phase &

one for neutral)

Three phase box 4 Sets (Three for Phase

& One for Neutral).

11

Length of Copper

Bus Bar with

Tin/Silver Plating

Single phase 1+9 : -

210 mm

Three phase 1+3 : - 84

mm

12 Pressure Plate Thickness 2.0mm

stainless



13 Insulation level

2.5KV A.C. R.M.S. as

per IS: 8623 (Part I)

1993

14 Earthing Plate 1 No 1.2 mm Zinc

Passivated

15 Earthing Bolt As per requirement of

size M6×20 mm

16 Earthing Logo Earthing symbol

17 Distance between

BusBars

Center to Center

distance 35 - 40mm

18 Hinges

2 Nos. built in type

hinges, No screws/rivets

visible from outside.

19 IP Level IP 55

20

i Sealing U Clamp

2 Nos. 1.2 mm Zinc

passivated

ii Arrangement for

external lock Required

21 Mounting

channels MS

2 Nos. (1.6 mm Thick

sheet steel Zinc plated/

passivated)

22 Gland Plate 1 No. 1.2 mm Zinc

plated/ passivated

A Tolerances As per Drawing

B

Suitable for

incoming cable

size

50/35 Sq mm Aluminum

cable

C

Suitable for

outgoing cable

size

1.5 - 35 Sq mm

Aluminum cable

23 color Dark grey / gray/other

24 marking Property of MPPKVVCL,

Jabalpur in big font



38.0 TECHNICAL SPECIFICATIONS FOR SINGLE PHASE LT STATIC WHOLE CURRENT SOLIDS STATE ELECTRONIC ENERGY METERS WITH BACKLIT LCD DISPLAY 38.1 SCOPE:-

(a) This specification covers design, engineering, manufacture, stage-inspection, testing and supply of A.C. Single phase two wire current rating 5-30 Amp solid state (static) whole current electronic LT energy meters of accuracy class 1.0 with backlit LCD display and communication port for data downloading as per requirement given in this specification. The meters shall be supplied in a push fit type meter box made of transparent engineering plastic, which shall be weather proof having flame retardant properties conforming to relevant specification. The meter and push fit type meter box shall be supplied in suitable packing so as to withstand transit shocks during road transport.

The meters should be suitable for single phase two wire system, capable to record and display monthly average p.f., energy in KWH, and demand in “KW” including other electrical quantities. The meters shall be capable to record over full power factor range of Zero Lag-Unity- Zero Lead, as per requirement given in this specification. These LT Meters should record total energy at basic frequency & harmonics. In addition the meters shall have provision for recording time of day (TOD) energy parameters.

(b) It is not the intent to specify completely herein all the details of the design and construction

material. However, the material shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the employer, who will interpret the meanings of drawings and specification and shall have the right to reject any work or material which in his judgment is not in accordance therewith. The offered materials shall be complete with all components, accessories and required software’s necessary for their effective and trouble free operation in the System for measurement of electricity supplied to the consumers. Such components shall be deemed to be within the scope of Bidder’s supply irrespective of whether those are specifically brought out in this specification and/ or the commercial order or not.

(c) It is compulsory that the offered LT meters shall bear BIS certification i.e. the meters shall be ISI

marked and the bidder shall have to furnish valid ISI license along with the offer, which, if considered necessary, may be verified by the Employer.

38.2 STANDARDS:

These LT meters and the associated accessories shall conform in all respects to the following relevant Standard Specifications with latest amendment there to:-

Indian Standard No. Title

IS:13779-1999 read with latest amendments

Specification for AC static watt hour meter for class 1 & 2

CBIP Technical report No.88 (with latest amendments)

Specification for AC static Electrical Energy Meters

IS:5133-1969 (Part II) Specification for boxes for the enclosure of electrical accessories

IS:9000 Basic environmental and other Testing for Electronic & Electrical items.

IS:11731 Specification for engineering plastic IS: 11000 Resistance to heat & fire CEA Regulation On installation of meters of. 17/03/06

38.3 SERVICE CONDITIONS (CLIMATIC CONDITIONS):

(i) The LT meters to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot, cold, tropical and dusty climate and solar radiation typically existing in State of M.P. The LT meter shall be required to operate satisfactorily and continuously under the following tropical climatic conditions:

(a) Maximum ambient air temperature 55oC (b) Maximum ambient air temperature in shade 45oC (c ) Maximum temperature attainable by the meter exposed to sun 60oC (d) Minimum ambient temperature (-) 5oC



(e) Average daily ambient air temperature 40oC (f) Maximum relative humidity 95% (g) Number of months of tropical monsoon condition 4 months (h) Maximum altitude above mean sea level 1000 meters (i) Average annual rain fall 150 cms (j) Maximum wind pressure 200 kg/sq.m (k) Isokeraunic level (days per year) 40 (l) Seismic level (horizontal accn.) 0.30 g (m) Permitted noise level 45db

All the parts & surface, which are subject to corrosion shall either be made of such material or shall be provided with such protective covering and finish, which ensures total protection from any injurious effect of humidity.

38.3 PRINCIPAL PARAMETERS:

These LT meters shall conform to the following specific parameters:

Sl. No.

Item Specification

1. Type of installation Indoor/Outdoor 2. System voltage (phase to

neutral) 240V + 20% to - 40% neutral solidly grounded.

3. System frequency 50 Hz ±5% 4. No. of phases 1 phase 2 wire (single Phase +Neutral) 5. System earthing Solidly grounded 6. Resistance to surge voltage of

1.2/50 Micro sec. As per relevant IS

7. Test voltage at 50 Hz 4KV RMS for 1 minute including latest amendments in relevant IS.

38.4 CONSTRUCTIONAL REQUIREMENTS:

The meters including meter case and push fit type meter box shall be fully transparent designed and constructed in a manner to avoid any danger during use under normal working condition including personal safety against electric shock. The meter case and push fit type box should comply following parameters:-

38.5 MATERIAL USED FOR METER CASE AND PUSH FIT TYPE METER BOX: i. The meters shall have a case, which shall be solidly welded to the meter base so that

access to the internal parts should not be possible without breaking the meter case. The material of meter body (base and cover) shall be made of Engineering plastic.

ii. The meter casing material should be glass reinforced, flame retardant, unbreakable engineering plastic material to ensure high reliability, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature. The material should be corrosion resistant, inert to chemicals, oxidizing agents, petro-chemical products, acids, salts and ultraviolet radiation. The meter chamber shall be dust proof and moisture proof. The supplier should indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The meter base and cover should be sturdy enough to prevent damage during transportation and installation.

iii. The engineering plastic used shall conform to IS: 11731 besides meeting the test requirement of heat deflection test and as per IS 11000(Part2 sec1) for resistance to heat and fire as per glow wire test specified in the relevant standard.

iv. All electrically live screws shall be of heavily tinned brass/nickel or zinc plated steel. All other screws shall be electro plated.

v. The terminal inserts shall be of heavily tinned brass/ nickel or silver plated copper, zinc plated steel.

vi. The meter shall conform to the degree of protection IP51 of IS: 12063 for protection against ingress of dust, moisture and vermin.

vii. The meter should be immune against jump during sudden switching of heavy loads or transient voltage spikes.

38.7 RATINGS:



The LT meters as specified in scope of this tender shall be rated as follows:

(a) Voltage 240V (b) Current (i) Basic current (Ib) 5A (ii) Rated max. continuous

current (Imax) 30A

(c ) Frequency 50 Hz (d) Accuracy Class 1.0

38.8 POWER SUPPLY VARIATION: The extreme power supply variations which the LT meter should withstand without damage and without degradation of its metering characteristics, as it operates under its normal operating conditions would be as under:

Voltage +20% to – 40% of rated voltage Current 120% of Imax. Frequency ± 5% of rated frequency PF range Zero (lag) – unity – Zero (lead)

The LT meter shall work over wide PF range and the limits of errors with the variation of PF shall be as per CBIP 88 (latest amendments)/IS: 13779

38.9 POWER CONSUMPTION:

38.9.1 Voltage Circuit: The active and apparent power consumption in each voltage circuit (per phase) including power supply of LT meter at reference voltage, reference temperature and reference frequency shall not exceed 1.5 Watts and 8 VA respectively as per IS:13779.

38.9.2 Current Circuit: The apparent power taken by each current circuit (per phase) at basic current, reference frequency and reference temperature shall not exceed 4 VA as per IS:13779.

38.9.3 Auxiliary Power: The LT meter shall draw power for working of electronic circuit from phase & neutral.

38.10 STARTING CURRENT: The LT meter should start registering energy at 0.4% of basic current at UPF as per IS: 13779. 38.11 RUNNING WITH NO LOAD:

When 115% of rated voltage is applied with no current flowing in current circuit, the test output of the LT meter shall not produce more than one output pulse count as per IS: 13779.

38.12 INFLUENCE QUANTITIES: The single & three phase LT meter shall work satisfactory with guaranteed accuracy as per

limit prescribed in IS:13779 under presence of the following quantities:- (i) External magnetic field (ii) Electromagnetic field (iii) Radio frequency interference (iv) Vibration (v) Harmonic wave form (vi) Voltage fluctuation (vii) Electromagnetic high frequency field 38.13 TEMPERATURE RISE:

(a) Under normal conditions of use at Imax current, winding and insulation shall not reach a temperature, which might adversely affect the operation of these LT meters.

(b) With each current circuit of the meter carrying rated maximum current and with each voltage circuit (and those auxiliary voltage circuits which are energized for periods of longer duration than their thermal time constant) carrying 1.20 times the rated voltage, the temperature rise of the external surface shall not exceed by more than 20ºC, with the ambient temperature between 25ºC to 45ºC.



38.14 LIMITS OF ERRORS:

When the LT meter is under reference conditions, the percentage errors shall not exceed the limits as specified in IS: 13779.

38.15 DISPLAY:

The LT meters shall have bright LCD Electronic display with backlit & with minimum 6 digits to read up to one tenth of KWh with another digit for legend. The decimal digits shall be clearly distinguished from integer digits. The backlit should not glow during power off condition. The LCD shall be of STN (Super Twist Nematic) type designed suitably to withstand temperature of 80oC (storage) & 65oC (operation).

(i) When the LT meter remains at a constant temperature of 65oC for a period of 30 minutes, the character of LCD should not deform.

(ii) After keeping the LT meter at a constant temperature of 80oC for a period of 30 minutes and when restores at normal temperature, LCD display should work as in normal conditions.

The LCD display should have a wide viewing angle of 45o to 60o up to one-meter distance, for clear visibility of the display of the meter reading. Large viewing area with large display icons is desired. The registered parameters shall not be affected by loss of power. The display shall not be affected by electrical and magnetic disturbances. The meter shall make use of non-volatile memory capable of storing and retaining all the data required to be stored, without the help of any power source or battery back up and shall have a minimum retention time of 12 years under un-powered condition. The minimum character height X width shall be 8.5 X 5 mm for whole digits of kWh Display. Dot-Matrix type LCD display is not acceptable. The accuracy of display for all parameters shall be matching with the accuracy class of meter as per IS.

The display of various parameters in push button mode shall be scrolling one after another.

The display shall have ON time of at least 10 seconds for each measured value. The meter shall be capable to measure and display continuously “Active Energy KWh” at all

loads and in full power factor range of zero lag- unity- zero lead. The LT meter should also have provision for automatic recording and storing of required parameters at 24.00 Hrs on the last day of the month for each calendar month and the same should go to memory.

38.16 DISPLAY SEQUENCE:

The Liquid Crystal Display register for single and three phase LT meter should display the measured value(s). The height of the display character should be minimum 8.5 mm. In addition display of the required parameters should be in two different modes as stated hereunder:-

38.17 AUTO SCROLL DISPLAY MODE: The LT meters shall have following parameters in auto scroll display i) Date: DD: MM: YY Real Time: HH:MM ii) Cumulative Active Energy KWH i) Instantaneous load in Watt.

38.18 DISPLAY PARAMETER (PUSH BUTTON) MODE:

The display of the following parameters shall be scrolling one after the other through push button. The display shall have ‘ON’ time of minimum 10 seconds of each measured value, except LCD segment check. The LCD segment check shall be on meter display for minimum 2 seconds. Display parameters shall move forward if button is pressed prior to the programmed time for display of each parameter.

(a) LCD segment check (b) Meter serial number (c) Real date and time (Date DD-MM-YY, Time HH-MM) (d) Cumulative active energy (KWH) register. (e) Maximum demand of the month in KW by default up to two decimal (since last auto

reset) with date & time with 15 minutes integration period. (f) Cumulative active energy KWH for each calendar month for previous six months with

programmed billing date.



(g) Maximum Demand in KW up to two decimal for each calendar month for previous six months with date and time of such demand

(h) Average P.F. for each calendar month and for previous six months. (i) Tamper information- this shall be displayed when tampered with following. (a) Date of last tamper occurrence. (b) Time of last tamper occurrence. (c) Number of time meter tampered. (j) Instantaneous phase voltage (k) Instantaneous line current (l) Instantaneous p.f. (With sign of lead/lag) (m) Instantaneous load in Watt (n) High resolution Energy value (resolution will be sufficient to enable conduction of the

starting current and accuracy test in less time.) Since meters are required duly fitted with push fit type meter box, hence for reading purpose, an arrangement should be made on top cover of push fit type meter box with its mechanical connection to the meter’s body as described in the Specification of meter box to activate the display push button of meter. The display with push button shall be auto off type after completion of the display cycle it should revert back to normal auto scroll mode approximately after 10 seconds. Fresh button press will be required after resumption of auto scroll cycle to display the above parameters again.

38.19 METER READING DURING POWER OUTAGE: The meter shall have provision to read the meter in no-power condition. The same push button shall be used for display of parameters of. auto scroll mode during power outage. In any case, RTC Battery Power shall not be used for display under no-power condition.

38.20 LCD LEAST COUNT:- The kWh display shall be with one decimal digit in push button mode and in auto scroll mode. The internal least count of the energy recording shall not be more than 0.01 KWh. and every 0.01 KWh, consumption shall be internally stored.

38.21 COMMUNICATION CAPABILITY

The meter shall have wireless communication facility for remote reading through infrared Communication Port. The meter shall have facility for communicating with a hand held terminal (HHT) i.e. Meter Reading Instrument (MRI) through this port to facilitate for auto-reading and downloading the data for billing and historical data to base computer. Arrangement shall be made to get such a reading even at the time of power failure. The interface for communication between MRI & Base computer shall be supplied free of cost. The software required for MRI and Base Computer System with necessary security provisions shall also be supplied free of cost with the following features:

a. It should be possible to read the meter through external MRI via infrared media from a minimum distance of 1.5 metres in front of the meter box.

b. It should not be possible to reset the energy reading in the meter or make any change in the data stored in the meters either current or historical, with the MRI.

c. The infrared module of the meter shall have no physical access from outside the meter. d. Infrared transmitter and receiver should be compliant to the latest IrDA Physical Layer

Standard.

e. The compatibility of transferring data from the meter to MRI and then to the base computer system (BC) should be easily established; any change in language or any other reasons, the supplier shall modify it at his own cost within the guarantee period.

f. For the purpose of data security, the data transfer from the meter to CMRI and further to Base computer should be fully secured and any unauthorized attempt/change in data should be indicated on computer system. There should be multi level password on the base computer system and in the meter to prevent any unauthorized change of billing parameters, resetting of demand and tamper in formation.

38.22 BILLING POINT REQUIREMENTS:

The predefined date and time for registering the billing parameters of energy, PF and MD as well as Tamper Count and Power-On hours details shall be at 00.00 hours of the first day of



each calendar (billing) month and all the billing parameters shall be transferred to billing registers. The above billing data, TOD register's data, tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details.

38.23 TOD TARIFF/DEMAND

The meter should be capable of registering the time-of-day energy (TOD) and maximum demand. The time registers shall be programmable by the purchaser. The meter should have in-built capacity to define up to six registers. The meter should also have capacity to define multiple time zones within the registers. The change of the TOD time-period(s) or defining TOD registers should be possible through CMRI with special authenticated command from the BCS so that only authorized person(s) can make such changes. The main control of this system along with proper security password/code should be available on one or more computers located at the authorized location(s) as per the directions to be given by the Purchaser.

Provision should be made for automatic reset of maximum demand at the end of pre-defined period (e.g. end of the month). The billing parameters at the time of automatic reset of MD shall be programmed such that it will transfer from rate registers to their respective billing registers. The main control of this system along with proper security password/code should be made available on one or more identified computers located at the authorized location(s) as per the directions to be given by the Empployer.

Necessary compatible meter application software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above shall be provided by the supplier. No separate cost will be borne by the purchaser on this account.

38.24 TEST OUTPUT DEVICE:

The LT meters shall have a test out put device in the form of calibrating LED of red colour having minimum intensity 10 M (Milli-candela) accessible from the meter front and shall be capable of being monitored conveniently with suitable testing equipment while operating at site. The location of the calibrating LED should be such that the calibrating pulses can be sensed easily through sensor for site testing of the LT meter’s accuracy.

The LT meters shall also give high-resolution energy values on the display. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time.

38.25 BASE COMPUTER APPLICATION SOFTWARE:

For efficient and speedy recovery of data read through CMRI/HHU, Base computer software shall be supplied having the following specifications stated as under:

The BCS software shall be user friendly Windows based. The Base Computer software shall give all details adequate for analysis. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. It should be possible for the Purchaser to generate its own DBF (data base files) to down load all the required information into it.

Platform: The BCS shall be executable on all WINDOWS system. The BCS shall be suitable to run on IBM compatible PC hardware platform.

Meter Data Display: The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram)

All the information about energy, maximum demand and their respective TOD register reading, billing register readings shall be shown in a manner which user can easily understand.


Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. All information about a particular



consumer will be sorted out and available at one place so that locating any consumer’s past data is easy. It shall be possible to retrieve/locate data on the basis of either one of the following particulars:

Consumer's ID/Numbers. Meter Sr. No. Date of meter reading. Location.

Data Transfer: It shall be possible to transfer data to and fro from CMRI through serial interface.

Configurability: It shall be possible to have selective printing of all available data of the meter. Print out shall not include anything and everything available with the BCS. The software shall support "print wizard" whereby user can decide what to print out. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires.


Security: The BCS shall have multilevel password for data protection and security. The first level shall allow the user to enter the system. The different software features shall be protecting by different passwords. The configurable of passwords shall be user definable. The software installed on one PC shall not be copy able on another PC.

Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents.

38.26 COMMON METER READING INSTRUMENT (MRI)

The Bidder should carefully note that a. The MRI shall be supplied in the ratio of one for each 200 nos. of meters free of cost

along with battery charger.

b. The MRI shall have facility to store minimum 1000 nos. of meter’s data. Further, there should be a facility in MRI to provide the transfer of meter data to computer through RS 232 or USB port.

c. The MRI shall be capable for down loading readings of other makes of meters. The bidder shall give an undertaking to this effect.

d. The MRI shall have possibility to read all of the three communication types of meters purchased by MPPKVVCL – optical port, infrared. MPPKVVCL shall exchange the communication protocols of successful bidders.

e. The infrared mode of MRI shall have a feature to read multiple meters within the range without pre-programming the meter serial numbers in advance.

f. The data download time shall not exceed 5 (+2) sec per meter.

g. After successful downloading, indication shall be available on both meter and MRI and repeated downloading from the same meter shall be disabled for a minimum period of 5 min.

h. The communication software shall be capable to transfer the billing data and meter serial number required for automatic Spot Billing Machine to automatically generate the energy consumption bills at consumer premises without any human intervention after the data is collected by the MRI. The MRI shall continuously transmit the data until an acknowledgement is received from the SBM (Spot Billing Machine). The manufacturer shall provide the protocol and other information to interpret the transmitted billing data. The data storage inside the MRI and communication of MRI with the meter shall be encrypted so that there is no possibility of tampering with the downloaded data.

It shall be responsibility of the meter manufacturer to provide the required software and all the facilities and support required by the purchaser, to use the CMRI for reading and retrieving the data from the meter and to download the data to Base Computer on free of cost basis till the expiry of guarantee period.

38.27 READINGS TO BE DOWNLOADED WITH CMRI:



The CMRI should support in down loading all-important data stored in meter whether specified or not required essentially for deriving billing parameters including MD parameters. The following minimum parameters should be downloaded by CMRI.

i. Sr. No. of meter

ii. Date & Time

iii. Instantaneous current

iv. Instantaneous voltage

v. Cumulative Active energy (KWh)

vi. MD during the month

vii. Instantaneous load in Watt

viii. Instantaneous Power factor (sign of lag or lead)

ix. Cumulative active energy in KWh for the last 6 months

x. Maximum demand in KW for the last 6 months up to two decimal

xi. Average PF of the last 6 months

xii. TOD 1,2,---,6 Cum. KWh register(Programmable)

xiii. TOD 1,2,---,6 MD register KW up to two decimal (Programmable)

xiv. TOD 1,2,---,6 Billing MD registers

xv. TOD 1,2,---,6 Billing KWh registers

xvi. Tamper information including cover open tamper

xvii. Any other information whether specified or not, which is in the opinion of manufacturer is necessary for satisfactory performance of the meter, the manufacturer shall indicate such features in their offer without demanding additional cost.

The LT meter shall possess a suitable fast and reliable Infrared communication port for automatic transfer of data from Meter to CMRI. Arrangement in the meter should be such that, in case of failure of power supply, it should be possible to download the data.

The CMRI shall possess easily replaceable battery and shall be capable of storing data for at least 1000 nos. meters at one time. The total downloading time (from meter to MRI) shall not exceed 5 sec for each meter (with +2 sec. max tolerance time).

The CMRI shall possess a specific serial number, which cannot be changed/ altered.

The downloaded data along with date and time stamp of such reading shall remain on CMRI with suitable encryption and it should not be possible to pre-program or manipulate the recorded data on the CMRI before downloading the same on computer. The Supplier shall supply Software (compatible with Windows 98 system and/or higher) and training, free of cost for the use of software at multiple data collection and billing premises of the utility.

After successful downloading of meter data to CMRI, an indication on MRI or meter or both for confirmation of successful data transfer shall be provided. During this period the energy recording should not be affected.

Necessary upgrades shall be possible in CMRI software and shall be supplied free of cost for downloading simultaneously the existing parameters and any parameters added in future specifications of meters. A copy of operation manual shall be supplied along with each CMRI.

The Supplier shall provide meter-reading protocols free of cost, which shall not be complicated and shall be easily understandable by utility officials to ensure compatibility between meters and CMRIs of different makes.

38.28 MAXIMUM DEMAND REGISTRATION AND MD RESETS:

The Meter shall continuously monitor and calculate the maximum demand at the point of supply, during any consecutive 15 minutes during the calendar month . It shall store the maximum demand with date and time, when it occurred. The maximum demand shall automatically reset at 24.00 Hrs of the last date of each calendar month for which minimum 30 years calendar shall be programmed by the manufacturer.

Maximum demand of the month shall be in KW up to two decimal digits.



38.29 REAL TIME CLOCK AND BATTERY:

The MD integration cycle shall be on the basis of Real time clock of the meter. The maximum drift in real time clock of the meter shall not exceed ± 3 minutes per year and crystal should be temperature compensated for temperature range of 0oC to 50oC. A lithium battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition. The metering data stated above including integration etc shall be independent of battery. The minimum life of battery should be ten years.

38.30 CALIBRATION:

The meters should be software based factory calibrated and there shall not be any mechanical adjustment in calibration after freezing the parameters at works. This is to ensure that the meter cannot be calibrated at site.

38.31 CONSTRUCTION:

Meter shall be designed and constructed to be capable of withstanding all severe stresses and vibration and dust environments likely to be encountered in actual field conditions. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating.

38.32 TERMINALS AND TERMINAL BLOCK:

The terminals may be grouped in a terminal block having adequate insulating properties and mechanical strength. The terminal block should be made from best quality non-hygroscopic, flame retardant material (capable of passing the flammability tests given in IS:11731) with nickel plated brass for connecting terminals. It shall be an integral part of the meter base.

Terminal holes shall be of minimum 6.5mm to accommodate the insulation of conductor and shall be of adequate length in order to have proper grip of conductor with cage clamp arrangement /crimping pins with the help of two screws such that there is no risk of loosening or undue heating. Electrical connection shall be so designed that contact pressure is not transmitted through insulating material. Required number of pins along with one additional pair shall be supplied with each meter.

Sufficient clearance shall be allowed between terminals. Further, the supporting webs between the two terminals of the terminal block should be sufficiently high to ensure that the two neighbouring terminals do not get bridged by dust or it is not possible to have flashed over between adjacent terminals of terminal block.

The terminals shall be of suitable rating to carry 200% of Imax and shall be made of electro-plated (or tinned) brass.

All connection screws and washers should be tinned/ nickel-plated brass/ Zinc plated steel. The terminal screws shall not have pointed end at the bottom. All terminals shall have two screws. The terminals shall be properly bound in the insulating material of terminal block.

The terminal block shall have provision with single/two screws for fixing to the meter board. It shall not be possible to remove the meter from the hanging screw without removing the screws from the terminal block.

The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. A firm connection shall be established within the meter case to energize the voltage/current circuit. The connections shall be as per the recommended methods given in IS-13779.

38.33 CURRENT AND VOLTAGE CIRCUITS:

The current and voltage circuits shall be made of appropriate material such as enamelled copper wire of EC grade. The current circuit shall be appropriately insulated and potential circuit shall be appropriately encapsulated. The cross section of current circuit shall be designed to withstand the temperature rise of 50oC over the ambient temperature at maximum current. PT less design shall be used for power supply to PCB. The meter design shall be based on CT or CT and shunt combination or shunts. It is necessary to ensure accurate recording by the meters during the condition when DC component exists in the load, EM CT/Shunt currents should be compared and higher of the two should be used for measurement. Specific confirmation shall be submitted by the bidders that accuracy of measurement will not suffer due to utilization of shunt on account of thermal variation and temperature coefficient up to an operational temperature of 80oC.



38.34 CT/SHUNT FIXING ARRANGEMENT:

The CTs/Shunts & other measurement devices when provided in the meter shall be mounted through proper fixing arrangement so that it should have a firm support and should not move from its position in any case.

38.35 METER FIXING ARRANGEMENT:

Every meter shall have at least three fixing holes one at the top and two at the bottom. The top hole shall be provided with a special clip at the back of the meter so that holding screw is not accessible after the fixing of the meters. The lower fixing screws shall be provided under the terminal block. The requisite fixing screws shall be supplied with each meter.

38.36 CONNECTION DIAGRAM & TERMINAL MARKINGS:

The connection diagram of the meter shall be clearly shown on the nameplate of meter and shall be of permanent nature. The meter terminals shall also be marked and this marking should appear in the above diagram.

38.37 TERMINAL ARRANGEMENT:

Connecting terminals of the meter shall be in the following sequence: Phase (in) Neutral (in), Neutral (out), Phase (out) 38.38 NON FLAMMABILITY:

The terminal block, and the meter case shall be such as to ensure reasonable safety against spread of fire. It shall not be ignited by thermic over load of live parts in contact with them. To comply with this requirement, all the parts shall fulfill the conditions of the glow wire test as per relevant standard.

38.39 SEALING ARRANGEMENT:

The meters should be software calibrated at factory and sealed suitably before dispatch. The meter shall be provided with 2 nos. polycarbonate tamper evident seals which shall be

marked with “MPEZ”, company logo and shall be additionally laser marked with serial no. matching with that of meter. The serial number of meter is to be laser–etched on the base as well as the cover of the meter box, and can be easily viewed to check duplication attempts for the purpose of keeping track of meter seals. All the seals should be provided on front side only. Access to the working part should not be possible without breaking the seals.

The provision shall also be made to provide additional lash wire seals on the meter body by the MPPKVVCL.

38.40 TAMPER AND FRAUD PROTECTION:

Logics for design of various tampers, the value of voltage, current, time etc. to be selected for design of tamper shall be done in consultation with the purchaser. It may be noted that the approved logics used in designing tampers are explained to our field officers, and based on their input the bidder have to modify logic if necessary (The last tamper date and time of occurrence and tamper counts must appear in the DISPLAY and rest of the details in VIEW PARAMETERS).

The meter shall record and store last 100 events of tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. The event recording shall be roll over type i.e. it shall always maintain record of last 100 events occurred of selected tampers for logging.

The meter should have tamper & fraud protection features and shall record selected tamper information with date & time stamp. The meter shall continue to register active energy accurately even under following conditions:

The meter should register energy consumption correctly in forward direction irrespective of the direction of current in the current circuit (i.e. input and output interchange, phase and neutral connections interchange etc.).

38.41 Load Earthing:

(i) The meter shall record correctly when earth is used as a return path for load fully or partially even when phase and neutral connection are reversed.



(ii)When incoming neutral is disconnected, outgoing neutral is connected to earth through resistance and load is connected to earth, the arrangement should be provided such that power LED starts blinking when incoming voltage is below 200 Volts. The energy register shall advance for low voltage up to 120 Volts.

38.42 Neutral Missing:

The single-phase meter should register energy even if both the incoming and outgoing neutrals are disconnected and load is drawn through local earth. This should be irrespective of the position of phase. The threshold current for this feature should not exceed 20% of Ib and the assumption should be rated voltage, rated frequency and Unity power factor in proportion to the current drawn, as per class of accuracy of meter. Meter shall have provision to record the tamper of Neutral Missing with date and time of occurrence and restoration.

The meter shall record energy proportional to the current and rated voltage with Unity pf when any of the enclosed tamper circuits are used to tamper energy by more than 10% using a diode, or a variable resistance or a variable capacitance. The meter will be tested in these conditions such that the measured terminal voltage is reduced by 10%, 20% and 30% of rated voltage. The meter accuracy at 0.3 lag and 0.5 lead power factor shall be verified immediately after this test.

38.43 Cover opening :

If attempt is made to open the meter body, the meter shall detect /log with date and time of meter body opening tamper, even in absence of supply. This tamper shall also be displayed on the meter LCD with tamper information.

38.44 DC Immunity:

The meter should not saturate on passing of direct current which can cause the meter either to stop recording or record inaccurately as per IS: 13779 (latest version).

38.45 External Magnetic Influence:

The meter shall not get influenced by any external magnetic fields (AC Electro Magnet or DC Magnet) in accordance with the test procedures specified in IS: 13779 with its latest amendment for AC Magnetic Field. However, the meter alone should comply up to 0.27 Tesla DC.

The meter accuracy or accuracy in display under normal conditions shall not be affected by placement of a permanent magnet of not less than 0.27 Tesla anywhere on the surface of meter without meter box.

Meter shall have provision to record the tamper of abnormal magnetic induction with date and time of occurrence and restoration.

On application of external DC magnetic field of higher intensity against which meter is not immune, the meter should log the events of abnormal magnetic induction with date and time. The positive error may be beyond the limit of 4% but not exceeding power value equivalent to the product of rated voltage and maximum current.

38.46 Application of abnormal voltage /frequency:

A) The accuracy of the meter, Real time clock disturb, Memory data corruption, meter functioning hang up etc. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0.01-10 mm spark gap in any of the following manner when applied for 10 minutes:

a) On any of the phases or neutral terminals b) On any connecting wires of the meter c) At any place in load circuit d) Spark on meter body.

B) Meter should also be immune for tamper by application of remote loop induction device

(jammer).



When meter is subjected to approx. 35 KV abnormal high voltage/ frequency burst and remote loop induction device (jammer), it should not hang and in case if it hang once it should remain hanged permanently.

38.47 EMC/EMI Test:

The meter shall also pass all EMC/EMI tests as per IS:13779 with latest amendments. Further the bidder shall carefully note and confirm that:

1. The measurement of meter shall not be influenced by injection of AC voltages/ chopped signal/DC signal and harmonics on the outgoing leads of the meter.

2. The meter shall not get affected by any remote device.

3. The bidder should furnish detailed explanation as to how the meter is able to detect/Protect recording the above tamper and fraud features with sketches and phaser Diagram. Additional features, if any, in the meter may also be clearly indicated.

Along with the tamper information, the meter shall also record the instantaneous values of voltages, currents and power factors to simulate and elaborate the existing condition during the tamper events.

38.48 LED INDICATIONS :

The following LED indications must be provided on single and Three phase indication:

(i) KWh indicator for Meter calibration - Red (Calibration LED-Imp/KWh) (ii) Input and output reversal - Yellow LED indicator or ICON on Indication /

current reversal LCD (iii) Earth Tamper indication - Green LED indicator or Icon on LCD (iv) Power supply ON and Phase indication - LED or ICON on LCD for line ‘ON’

All the LEDs shall be of low power consumption and distinctly visible from distance. Except KWh indicator, all the other indications may be provided as Icon on backlit LCD. The earth LED should glow only when measurement is through neutral circuit.

38.49 SALIENT FEATURES:

The meter shall have the following additional features. The meter shall be compact in design. The entire design and construction shall be capable

of withstanding stresses likely to occur in actual service and rough handling during transportation/loading/unloading etc. The meter shall be convenient to transport and immune to shock and vibration during transportation and handling.

The short time over current rating shall be 30 Imax for one half cycle at rated frequency as per clause No.9.2.3 of IS:13779.

The meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0.3lag and 0.5 lead power factor.

Meter shall work within accuracy up to max. loading up to 120%Imax.

Even if phase to phase voltage (i.e. 440 Volts) is applied for 5 minutes between phase and neutral of the meter, the meter should not get damaged and continue to record correctly within class 1.0 accuracy after restoration of normal supply.

The meter shall also withstand impulse Voltage without any damage in accordance with the clause 12.7.6.2 of IS: 13779:1999.

The meter shall make use of Non Volatile Memory capable of storing & retaining all the data required to be stored, without the help of any power source or battery back up.

Computation of demand shall be on the basis of Real Time Clock of the meter itself.

Provision shall be there to do the billing operation automatically at a predefined date by programming the meter.

Meters covered under this specification shall be fully static type with non-volatile memory to register various billing parameters and complete with other features as detailed out in this specification. Any other design meeting technical specification or features/accuracy etc.,



better than this specification and manufactured as per relevant IEC/IS/CBIP report shall also be acceptable.

Meter shall be suitable for accurate measurement and display of energy and other billing parameters within the specified limits of errors under balance and unbalanced load conditions in a poly phase network.

Indication shall be provided on display to show the healthiness of phase voltage.

The meter shall be fully programmable by the user for TOD timing and billing dates etc. For security reasons the meter operating software should have at least “two level write protection” against any modification/editing of the parameters, data, settings etc. except those required for billing data, TOD metering.

The meter shall conform to the degree of protection IP51 of IS: 12063/IEC: 529 for protection against ingress of dust, moisture and vermin’s.

The meter base & meter cover shall be made of high grade, fire-resistant, non-inflammable high-grade and good quality engineering plastic.

The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling transportation. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling.

The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. A firm connection shall be established within the meter case to energize the voltage/current circuit. The connections shall be as per the recommended methods given in IS-13779

38.50 SELF DIAGNOSTIC FEATURE The meter shall be capable of performing complete self-diagnostic check and continuously monitor all the circuits for any malfunctioning and ensure integrity of data memory location at all time. The meter shall have display indication for unsatisfactory/nonfunctioning/malfunctioning of the following: a) Time and date on meter display b) All display segments on meter display c) Real Time Clock (RTC) status in meter reading print out at BCS end d) Non-volatile Memory (NVM) status in meter reading prints out at BCS end.

38.51 ELECTROMAGNETIC COMPATIBILITY AND INTERFERENCE REQUIREMENT:

The meter shall meet EMI/EMC requirements as specified in the relevant standards and shall also be protected against radiated interference from either magnetic or radio frequency sources.

The offered whole current meter shall also withstand DC Immunity test for main and neutral circuit at Iref = Imax/ root 2 as per IS:13779 so as to ensure that the meter current circuits do not saturate on passing of direct current.

The meter shall be designed in such a way that the conducted or radiated electromagnetic disturbances as well as electrostatic discharge do not damage or influence the meter.

The disturbance(s) to be considered are:

(viii) Harmonics (ix) Voltage dips and short interruptions (x) Fast transient burst test (xi) External D.C. and A.C. magnetic fields (xii) Electromagnetic H.F. fields (xiii) Electrostatic discharges (xiv) Radio frequency interference suppression.

` 38.52 GUARANTEED TECHNICAL PARTICULARS:

The bidder shall furnish all the necessary information as desired in the Schedule of Guaranteed Technical Particulars and data, appended with this specification. If the bidder desires to furnish any other information(s) in addition to the details as asked for, the same may be furnished against the last item of that Annexure.

38.53 NAME PLATE AND MARKING:



Every meter shall have a name plate clearly visible and indelible and distinctly marked in accordance with IS:13779 (latest version). The following information should appear on the name plate affixed on to the meter:- (i) Manufacturer’s name or trade-mark and place of manufacture. (ii) Designation of type (iii) Number of phases and number of wires for which the meter is suitable. (iv) Guarantee period – 5 years from the date of commissioning or 5-1/2 years from the

date of supply , whichever occurs first. (v) Purchase Order No. & Date. (vi) Property of MPPKVVCL. (vii) Bar coding of SN, Month & Year of manufacture (viii) Sign of Insulation Class (ix) Connection diagram (x) Serial number, year and month of manufacture (xi) Principal unit in which the meter records Reference voltage (xii) Basic current and rated maximum current (xiii) Reference frequency in Hz (xiv) Meter constant (Imp/KWh) (xv) Accuracy class (xvi) Reference tamperature (xvii) ISI mark and license number

38.53 TESTS:

(A) Type Test:

The type test certificate for all tests as indicated in IS:13779-1999 (with latest amendments) shall be furnished along with the bid. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. Type test report, amongst other details, should contain the following information clearly:

(i) Type of meter and display

(ii) Class of Accuracy.

Type test certificate from educational institute(s) will not be accepted. The type test certificate shall not be more than 24 months old as on the date of opening of bid.

(B) Additional Type Test:

In addition to the tests mentioned at (A) above, bidder shall have to furnish the type test reports of compliance of anti-tamper features as per tender specification.

(C) Acceptance tests:

All Acceptance tests as laid down in this tender specification shall be carried out.

(D) Verification during Inspection:

Inspecting officer shall verify that no DC supply/ signal is given to reference meter during the DC injection test. The accuracy of display parameters shall be verified at the time of inspection in line with class of accuracy of meter.

i. Voltage variation test

ii. Accuracy tests under all anti tamper conditions.

iii. Permanent magnet test

iv. Special accuracy test – the meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0.3lag and 0.5 lead power factor.

iv. The accuracy of the meter, Real time clock disturb, Memory data corruption, meter functioning hang up etc. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0.01-10 mm spark gap in any of the following manner when applied for 10 minutes:

a) On any of the phases or neutral terminals

b) On any connecting wires of the meter

c) At any place in load circuit



d) Spark on meter body.

v. Immunity from remote loop induction device (jammer)

The accuracy and above indicated parameters of meter shall be checked before and after the application of above device(s) with site conditions. It is desired that when meter is subjected to 35 KV abnormal voltage, frequency burst and remote loop induction device(jammer) it should not hang and in case if it hangs once it should remain hanged permanently.

(E) Routine Tests:

All the routine tests as stipulated in IS:13779 and in addition tamper and fraud protection tests as per TS shall be carried out and test certificates shall be furnished for approval of the Purchaser.

38.54 TEST FACILITIES AVAILABLE WITH THE MANUFACTURER:

The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Supplier shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials.

Bidders should carefully note that the standard meters used for conducting tests shall be calibrated periodically at NABL Accredited Test Laboratories and test certificates shall be available at Works for verification by Employer’s representative.

The Bidder/Manufacturer shall have at least the following testing facilities to ensure accurate calibration:

(i) Insulation resistance measurement (ii) Running at no load (iii) Starting current test (iv) Limits of error (v) Power loss in voltage and current circuit (vi) Repeatability of error (vii) Transportation test (viii) Low load run test (ix) Heating test

38.55 INSPECTION:

The Purchaser’s authorized representative may carry out the inspection at any stage of manufacture. The Supplier/Manufacturer shall grant free access to the Purchaser’s representative at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the Purchaser shall not absolve the Supplier of his obligation of furnishing the equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective.

All acceptance tests and inspection shall be made at the place of Supplier/Manufacturer. The Supplier shall provide all reasonable facilities without demanding any charge to the inspector representing the Purchaser to satisfy him that the equipment is being furnished in accordance with this specification.

The Supplier/Manufacturer shall keep the Purchaser informed in advance, about the manufacturing/readiness activities so that arrangement can be made for inspection.

The Purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items. The Supplier shall give 15 days advance intimation to enable the Purchaser to depute his representative for witnessing the acceptance and routine tests.

The Purchaser reserves the right to get type tests done in respect of any meter, or Box from any of the lots received at any Destination Stores at Supplier’s expenses.

38.56 SAMPLE:

Sample before Commencement of supplies: The Supplier shall submit sample of offered meter along with the meter box having all the features conforming to the prescribed specification for our approval before commencement of supply.



38.57 RANDOM SAMPLE TESTING AFTER RECEIPT OF METERS AT STORES:

The consignment of meters received at Area Store shall be accepted only after testing of sample meters at CPRI as stated in following paras. The sample meters shall be selected randomly from the lot and will be sent to CPRI for acceptance test as per relevant ISS and as per procedure prescribed in following paras. If the sample fails in the above tests, the entire lot will be rejected and testing charges shall be recovered from the supplier. Purchaser may select meters at random from a lot of meters supplied and sent to CPRI/ERDA/ERTL/any NABL accredited testing laboratory for acceptance test as per relevant ISS. If the sample fails in the above tests, the entire lot will be rejected and testing charges shall be recovered from the Supplier.

38.58 QUALITY ASSURANCE PLAN:

The designed life of the meter shall be minimum of 20 years and to prove the designed life, the firm shall have to follow at least the following Quality Assurance Plan:-

(i) The factory shall be completely dust proof. (ii) The testing rooms shall be temperature and humidity controlled as per relevant standards.

The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates.

(iii) Power supplies used in testing equipment shall be distortion free with sinusoidal, wave forms and maintaining constant voltage, current and frequency as per the relevant standards.

(iv) During the manufacturing of the meters the following checks shall be carried out. (a) Meter frame dimensions. (b) The assembly of parts shall be done with the help of jigs and fixtures so that human

errors are eliminated. (c) The meters shall be batch tested on automatic, computerized test bench and the

results shall be printed directly without any possibility of human errors. The Supplier/Manufacturer shall furnish the following information. Information shall be

separately given for individual type of meters offered.

(ix) Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list of standards according to which the raw materials are tested, list of tests normally carried out on raw material in presence of Supplier’s representative and copies of test certificates.

(x) Information and copies of test certificates as in (i) above in respect of bought out accessories.

(xi) List of manufacturing facilities available.

(xii) Level of automation achieved and list of areas where manual processing exists.

(xiii) List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.

(xiv) List of testing equipments available with the Supplier for final testing of equipment specified and test-plant limitations, if any, vis-à-vis type, special acceptance and routine tests specified in the relevant standards and this specification. These limitations shall be very clearly brought out in schedule of deviations.

The Supplier/Manufacturer’s laboratory must be well equipped for testing of the meters. They must

have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document.

38.59 MANUFACTURING ACTIVITIES:

(i) All the materials, electronics and electrical components, ICs used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability, longer life and sustained accuracy.

(ii) The Manufacturer should use Application Specific Integrated Circuit ASIC or Micro controller for metering functions.



(iii) The electronic components shall be mounted on the printed circuit board using latest Surface Mounted Technology (SMT) except power components by deploying automatic SMT pick and place machine and re-flow solder process. The electronic components used in the meter shall be of high quality. Further, the Supplier should own or have assured access (through hire, lease or sub-contract) of the above mentioned facilities. The PCB material should be of glass epoxy FR-4 grade conforming to relevant standards.

(iv) All insulating materials used in the construction of meters shall be non-hygroscopic, non-aging and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating.

(v) Quality should be ensured at the following stages :

(a) At PCB manufacturing stage, each board shall be subjected to bare board testing.

(b) At insertion stage, all components should undergo testing for conforming to design parameters and orientation.

(c) Complete assembled and soldered PCB should undergo functional testing using test equipments (testing zig).

(d) Prior to final testing and calibration, all meters shall be subjected to accelerated ageing test to eliminate infant mortality.

1. The calibration of meters shall be done in-house.

2. The Supplier/Manufacturer should submit the list of all components used in the meter along with the offer.

3. A detailed list of bought-out items which are used in the manufacture of the meter should be furnished indicating the name of firms from whom these items are procured. The Supplier shall also give the details of quality assurance procedures followed by him in respect of the bought-out items.

4. The details of testing facilities available for conducting the routine and acceptance tests and other special tests on the meter shall be furnished with the bid. The facility available if any for conducting type test may also be furnished.

38.60 DOCUMENTATION:

All drawings shall conform to International Standards Organization (ISO “A” series of drawing sheet/India Standards Specifications IS: 656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units.

List of drawings and documents:

The Supplier/Manufacturer shall furnish the following:

(i) Two sets of drawing clearly indicating the general arrangements, fitting details, electrical connections etc.

(ii) Technical leaflets (user’s manual) giving operating instructions.

(iii) Three copies of dimensional drawings of the quoted item.

The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the employer. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawing shall be at the contractor’s risk.

Approval of drawings by employer shall not absolve the contractor of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respect to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and Purchaser shall have the power to reject the materials which, in his judgment, is not fully in accordance therewith.

The successful bidder shall, within 2 weeks of notification of award of contract, submit three sets of final versions of all the drawings as stipulated in the contract for employer’s approval. The employer shall communicate his comments/ approval on the drawings to the contractor within two weeks. The contractor shall, if necessary, modify the drawings and resubmit three



copies of the modified drawings for approval. The contractor shall within two weeks, submit 10 prints and two good quality report copies of the approved drawings for employer’s use.

Sets of operating manuals/technical leaflets per 100 meters shall be supplied to each consignee in the first instance of supply. Additional copies of sets of operating manuals/technical leaflets in the numbers as may be desired by the employer shall have to be supplied to the consignee or field officers.

One set of routine test certificates shall accompany each dispatched consignment.

The acceptance test certificates in case of pre-despatch inspection or routine test certificates in cases where inspection is waived shall be got approved by the employer

38.61 GUARANTEE:

(i) The defect Liability period shall be as mentioned in clause GCC 27.10 of SCC of Section 8 of the bid document.

(ii) The meter found defective within the above guarantee period shall be replaced by the supplier free of cost within one month of the receipt of intimation. If the defective meters are not replaced within the above specified period, the same shall be treated as breach of performance of the contract and shall be liable for consequential penal action.

38.62 PACKING & FORWARDING:

The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The Supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Any material found short inside the packing cases shall be supplied immediately by Supplier without any extra cost.

Each consignment shall be accompanied with a detailed list containing the following information.

a) Name of the consignee b) Details of consignment c) Destination d) Total Weight of Consignment e) Handling and packing instruction f) Bill of material indicating contents of each package

The packing shall be done as per the Manufacturer’s standard practice. However, he should ensure the packing is such that the material should not get damaged during transit by Rail/Road.

38.63 GENERAL :

a) Principle of operation of the meter, outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate, if applicable, shall be furnished by the bidder.

b) The Supplier shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT, VT or potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period.

c) The Supplier shall furnish details of memory used in the meter.

d) The Technical Specification of Push Fit Type Meter Box Made Of Engineering plastic has been described in para 39.0.

e) The procedure for Verification/Testing of Material supplied described in para 39.1 shall be followed

f) It is mandatory to conform compliance of guaranteed technical particular of ac single phase electronic KWH meter with LCD display as described in para 39.2.



Tamper circuits



38.64 TECHNICAL SPECIFICATION OF PUSH FIT TYPE METER BOX MADE OF ENGINEERING PLASTIC

The meter box shall be weather proof, tamper proof and made of transparent engineering plastic conforming to IS: 11731. Type test of material is required to be furnished along with the sample.

The meter box should be unbreakable un-deformable and should withstand the temperature up to 140 deg. cent.

Thickness of the base should be at least 2 mm and cover should be of not less than 0.8 mm.

Clearance of 30 mm shall be maintained from top and both sides of the meter. However, the clearance at bottom should be of 75 mm. from the meter and 45mm from the terminal block. Besides, there should be minimum clearance of 15 mm in the front from the face of meter.

The top cover of the meter box should be of push fit type having at least 4 self locks so that once the top cover of the box is fitted with the base it cannot be removed without breaking the top cover. The cover and base shall have groove all along with the fitting edge, so that after fixing the top cover, no wire or any device can be, temporary or permanently, inserted in the box. The top cover of the box, provided with self-lock, should have arrangement/barrier so that after getting locked, it cannot be detached from latches even by applying external pressure through any means. The locks will be moulded in the cover and base and will not be separate pieces fixed later. There will be no holes to access the locks from any side.

Additional provision to provide lash wire utility seals on meter box shall be made.

Meter shall be fitted with the base of box through unidirectional type screw or by some other better means in such a way so that once the meter is fitted with the base; it cannot be removed from the base and become an integral part with base. The meters shall be supplied duly mounted on the base of meter box and the cover shall be placed separately in the cartoon.

Suitable circular holes with adjustable cable glands shall be provided at the bottom of the meter box for inlet and outlet of consumer’s service cables. The incoming and outgoing gland shall be positioned such that they disable direct access to terminals through glands.

The meter box cover or base shall have a barrier so positioned that any possibility of fiddling the meter terminal from outside of the meter box through cable entry holes is not possible. The barrier shall have reinforce/locked at both sides to restrict its movement up and down even by applying external pressure through any tools.

The top cover of meter Box should have spring loaded push button with spindle in moulded barrel perfectly in alignment to operate push button of the meter to read display parameter on push button mode.

The boxes shall be specific to the meter mounted in it. Thus, the Serial Number of the meter should be indelibly engraved /marked on the base of meter box as well as on the cover of meter box.

The box should have proper mounting arrangement so that it could be mounted on the wall or the pole, as the case may be.

The meter box comprises of base and cover shall pass the following tests;

i) Unbreakability test:- Shall not get damage or deform while dropping from a height of 10 ft. and hammered with 2 kg. hammer to test its unbreakability.

ii) Boiling water test :- It should pass the boiling water test as prescribed in IS:13010.

The overall dimensions of the meter box shall vary according to the different make of meters. However, it shall comply with the minimum requirements as described above.

The individual meter manufacturers shall submit the specific drawing and sample accordingly to accommodate there make meter only.

38.65 VERIFICATION/TESTING OF MATERIAL SUPPLIED

Three (3) sample meters shall be selected for conducting Type Test from the first lot of meters received in Contractor’s stores by a committee constituted by CE (W&P). The samples so selected shall be sealed by at least 3-4 seals/stickers by the committee members. The



selected samples shall be sent with complete details for type test and additional test/special tests as per specification at CPRI, Bhopal / ERDA, Vadodara / any NABL accredited test house. The type test charges shall be borne by the contractor. The employer however in first instance may pay testing charges to the testing agency, which shall be recovered by Dy. Director (Bills) from the bill of the supplier.

In case of successful type test results, supplies shall be continued. However, in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s), three more samples shall be selected from the supplies already received to get them type tested at contractor’s cost. In case of repeat failure in type test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled.

On receipt of consignment of subsequent lot in Contractor’s Stores, a set of 32 meters shall be selected randomly and sent to CPRI for conducting acceptance test as per the prescribed procedure

Following procedure shall be adopted to clear the tested lot:

1. Failure of any 2 nos. meters shall be allowed out of 32 nos. of meters tested at sr. no. (i) of above table. Failure of more than 2 nos. meters, the further testing shall be suspended and lot shall be declared as fail.

2. Failure of any one meter shall be allowed out of 8 nos. of meters tested at sr. no. (ii) of above table. In case of failure in more than one meter, the further testing shall be suspended and lot shall be declared as fail.

3. No failure shall be allowed out of 3 nos. of meters tested at sr. no. (iii) of above table. In case of failure of any meter, the further testing shall be suspended and lot shall be declared as fail.

4. Failure of any one meter shall be allowed out of 8 nos. of meters tested at sr. no. (iv) of above table. In case of failure in more than 1 no. meter, further testing shall be suspended and lot shall be declared as fail.

In case of failure of samples of lot/ sub-lot in the test(s) detailed above, the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the supplier at his own cost. Repeated failure/poor results in the testing may render cancellation of order.

The supplies, at the option of employer, may be utilized in the field during the period of testing. In case of repeat failure in acceptance test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost.

The employer also reserves the right to get additional samples for all or any of the selected tests at employer's cost at any independent test house at any stage of supply, if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. In case of failure, the guarantee period of the quantity already supplied by the supplier shall be doubled and employer reserves the right to cancel the balance quantity.

However, employer may allow the contractor to re-offer the material after change/ modification in the design of meters. The balance material shall be accepted only after successful Type Testing. The Type Testing charges shall be borne by the supplier.

In case of successful test results, supplies shall be continued.

S.No Particulars of tests No. of samples to be tested

(i) Starting Current test and No load test 32 Nos. (ii) AC high Voltage test, Insulation test, Limits of error, Test of meter

constant, Power consumption test. 8 nos. out of above 32 Nos.

(iii) Repeatability of error 3 nos. out of above 8 Nos.

(iv) Voltage variation, Tamper & fraud protection, D.C. Immunity Test, Magnetic Immunity test (Permanent magnet test of 0.27 Tesla), Accuracy test after application of 440 Volts for 5 minutes, Imax for 30 minutes test, D.C. Injection test, 35 KV abnormal high voltage/ frequency burst & loop induction device (Jammer) burst test, Shock test and Fast transient burst test.

3 nos. out of above 8 Nos.



The decision of MPPKVVCL regarding verification/ Testing of meters shall be final and binding on the supplier and the MPPKVVCL shall not be required to give any reason(s) in writing or otherwise at any time for the rejection of material.

38.66 GTP FOR AC SINGLE PHASE ELECTRONIC KWH METER WITH INFRARED COMMUNICATION & LCD DISPLAY

Sl. No.

Particular Min. Requirement Offered

1. Name of manufacturer

To be mentioned

2. Type, name & number (Model) To be mentioned 3. Standard Applicable IS:13779/1999, CBIP-88 with its latest

amendment as on date.

4. Rating (i) Accuracy Class Class-1.0 (ii) Rated Voltage 240V (+ 20% -40%) (iii) Rated current Ib-5 Amp. Imax 30 Amp (iv) Rated frequency 50 Hz ± 5% (v) Power factor Zero lag - Unity – Zero lead (vi) Shall work within accuracy

up to max. loading 120% of Imax

5. (i) Continuous current rating (Amp.) 30 Amps. (ii) Running with no load and 115 %

of rated voltage No creeping

6. Short time over current for one half cycle at rated frequency.

30 Imax

7. Starting current at which meter shall run & continue to run

0.4% of Ib at rated voltage and unity power factor

8. Power loss at rated frequency & reference temperature (a) Current circuit at rated current Less than 4 VA (b) Voltage circuit at rated current Less than 1.5W/8VA 9. Type of material used (a) Base Material and thickness High Impact strength, non-hygroscopic,

flame retardant, Engineering plastic of min. 2.0 mm thick

(b) Meter cover material ---As above --- (c) Terminal Block material High Impact strength non hygroscopic,

flame retardant material. Barrier of adequate size shall be provided between neighbouring terminals.

(d) Colour Meter cover shall be fully transparent. (e) Screw (i) Material Nickle Plated - Brass (ii) Size 5-6 mm dia 10. Internal diameter of Terminal Hole Min. 6.5 mm 11. Centre to Centre clearances

between adjacent terminals More than 13 mm

12. Transducers (i) Input CT/Shunt or combination and potential

divider (PT less)

(ii) Output Digital 13. Type of display LCD with Backlit (i) Operation suitability LCD suitable for operation up to 65o &

80oC as per TS

(ii) No. of Digits 6 including decimal digit (5+1) (iii) Size of Numerals (min.) 8.5 x 5 mm 14. Display Sequence ( display should be self explanatory) 14.1 Auto Scroll Mode (i) Date and

Time DD: MM: YY HH:MM

(ii) Cumulative active energy KWh (iii) Instantaneous load Watt 14.2 Push button mode (As per specification)



15 Type of push button arrangement Spring loaded push button to be provided

on top cover of meter box to activate the push button of meter to read parameters

16. (i)

Reading during power-off condition

Meter shall be able to display reading

(ii) Type of arrangement made to display in power off condition

Please provide

17. Battery of Real time clock (i) It shall be long life having at least 10 years of life

(ii) The drift in time shall not exceed ± 3 minutes per year

18.

Type of communication provided for data downloading shall be as per TS

Please indicate the type

19. Fixing/sealing arrangement (i) Fixing of meter Min. 3 fixing holes (one at top & two at

bottom under terminal block). The top fixing screw shall not be accessible after meter is fixed to meter box base.

(ii) Sealing of meter cover to Base (a) At least 2 nos. polycarbonate irreplaceable tamper evident seals which shall be marked with “MPEZ”, company logo and shall be additionally laser marked with serial no. matching with that of meter. The serial number of meter is to be laser –etched on the base as well as the cover of the meter box, and can be easily viewed to check duplication attempts for the purpose of keeping track of meter seals with serial no. matching with that of meter also marked with MPEZ and firm’s logo.

(b) provision shall also be made to provide additional lash wire seals on the meter body by the Utility

(c) Seals shall be provided on front side only.

(d) Meter cover shall be permanently and solidly welded with Base so that it could not be opened without breaking.

20. Performance of meter in tamper conditions (i.) Phase-neutral interchanged Should work within specified accuracy (ii) Main & load wire are interchanged ----do---- (iii) (a) Load is not terminated back to

meter & current is drawn through local earth fully or partially even when phase and neutral connection are reversed.

---do----

(b) Incoming neutral disconnected, outgoing neutral connected to earth through resistance and load is connected to earth.

LED start blinking when incoming voltage is below 200V and Energy register shall advance for low voltage up to 120V

(iv) Neutral disconnected from both incoming & outgoing and load drawn through local earth

Provision should be there not to exceed threshold current of 20% of Ib and start recording energy. Meter shall have provision to record the tamper of Neutral Missing with date and time of occurrence and restoration.

(v) The meter shall record energy proportional to the current and

when any of the enclosed tamper circuits are used to tamper energy by more than



rated voltage with Unity pf 10% using a diode, or a variable resistance or a variable capacitance

(vi) Indication in above tamper condition (LED or ICON)

“Reverse” indication for (i) & (ii), “Earthed” indication for (iii) above & (iv)

(vi) If attempt is made to open the meter body,

The meter shall detect /log with date and time of meter body opening tamper, even in absence of supply. This tamper shall also be displayed on the meter LCD

(vii) Application of abnormal frequency and voltage of the order of 35 KV voltage burst with the help of external device

Should work normal and the accuracy should not be affected after removal of such device. The meter should not hang during any desired method of test. The meter should not exhibit intermittent recording operation and if it hangs during any desired testing method, it should permanently remain hanged.

Meter should also be immune for tamper by application of remote loop induction device (jammer).

21. Suitability of meter to sustain over voltage i.e. phase to phase voltage injected between phase & neutral

Should sustain

22. Size of calibration LED and other LED/Icon

Low Power 3mm or 5mm. Calibration LED of Red colour is essential. Rest of the LED’s as per TS or Icon on LCD.

23. Electromagnetic compatibility (EMC/ EMI severity level)

Should withstand severity level 4

24. Effect on accuracy of external electromagnetic interference of electrical discharge, external magnetic field & DC current in AC supply or in neutral

Should work within accuracy complying with standards with its latest amendment as on date.

However for Immunity to external DC magnetic field, the performance of meter should not get affected on application of DC magnet of not less than 0.27 Tesla size at different locations of meter body.

• Under the influence of abnormal magnetic field (not less than 0.27T) the meter shall record energy not exceeding the product of rated voltage and maximum current (Imax).

• Meter shall have provision to record the tamper of abnormal magnetic induction with date and time of occurrence and restoration.

25. Effect of accuracy in tamper conditions

Should work within accuracy specified in IS:13779 with latest amendment

26. Cut off voltage (at which meter stop working)

Please specify

27. Ref. Temperature 27oC 28. Temperature range of operation -5oC to 60oC 29. Drift in accuracy of measurement

with time No Drift in accuracy in measurement with time

30. Fixing arrangement of name plate Plastic nameplate fixed in side the meter. It should contain all the details as per ISS

31. Type of body Projection type 32. Calibration Software calibrated at factory. 33 CT/Shunt fixing arrangement Please indicate 34. Manufacturing activity (i) Mounting of components on PCB

shall be SMT type SMT type and ASIC technology



(ii) Compliance to quality assurance Please confirm 35. Testing facility (i) Fully automatic meter bench with

print out facility shall be available. Must be available

(ii) Make and S.No. of Test bench To be indicated (iii) Accuracy of ESS ---do--- (iv) Type of technology Digital/Analog (v) Following in house testing facility shall be available; a) Insulation resistance Must be available b) Running on no load --do-- c) Starting current --do-- d) Limits of error --do-- e) Range of Adjustment --do-- f) Power loss in voltage and current

circuit. --do--

g) Repeatability of error --do-- h) Transportation test --do-- i) Low load run test --do-- j) Heating test --do-- 36.(i) Whether offered meter are Type

Tested as per IS:13779 at NABL accredited Lab

YES/NO

(ii) Name of the Lab Please provide 37. Guarantee period of meter printed on

name plate. 5½ years from the date of supply.

38 BIS licence No. & dt. With its validity for ISI certification mark on offered meter

Please provide

39 Details of meter design for which above BIS certification has been obtained: - (i) Ratio of Ib to Imax Please provide (ii) Material of meter body Please provide (iii) Type of energy registering counter Please provide (iv) Type of technology Please provide (v) Grade of printed circuit Board material Please provide (vi) Type of assembly of component used

(SMT) Please provide

(vii) Meter constant (Imp/KWh) Please provide (viii) Auxiliary power circuit (with PT or PT

less) Please provide

(ix) Current circuit (CT/Shunt combination or only shunt)

Please provide

(x) Accuracy Class Please provide 40. ISO accreditation no. & dt. with its

validity Please provide

41. Past Experience (i) Whether the details of orders

received and quantity supplied is indicated in the schedule of past experience.

YES/NO

(ii) Confirm whether copy of the orders along with technical specification is enclosed with the tender.

YES/NO

42 Whether meter has Six programmable Time of use facility

YES/NO

43. Other parameters/features not covered in the above GTP

Conform to Technical specification and IS:13779/1999 (with its latest amendment).



39.0 TECHNICAL SPECIFICATION OF 3 PHASE 4 WIRE STATIC

TRIVECTOR ENERGY METERS FOR DTR METERING

39.1 SCOPE: This specification covers the design, engineering, manufacture, assembly, inspection, testing at manufacturers Works before dispatch and supply of high precision three phase four wire

3x240 volt, 40-200 Amp static Electronic tri-vector energy meter of accuracy class 1.0, capable of primarily performing functions of tariff meters and GSM modem (GPRS enabled) with store and forward facility with suitable accessories for automatic and remote data transfer from Electronic energy meters. The complete meter unit i.e. meter, internal CTs and modem shall be housed in the same encloser. The meter shall have provision in such a way that LV side cable of Distribution Transformer shall be directly passed through the meter for current measurement. Piercing screws shall be used in the meter for voltage connection The meter should be capable to record and display active energy, apparent energy, reactive energy and maximum demand KW/KVA for 3 phase 4 wire AC balanced/ unbalanced loads for a power factor range of 0 lag, unity and 0 lead. Meters shall be supplied along with base-computer software’s (BCS) suitable to read the meter remotely as per the details given in this specification.

39.2 STANDARD APPLICABLE:

Unless otherwise specified elsewhere in this specification, the performance and testing of the meters shall conform to the following Indian/International Standards and all related Indian/International standards to be read with upto-date and latest amendments/revisions thereof:

Indian Standard No. Title International & Internationally recognized standard

IS:13779/1999 with latest amendment

Specification for AC static watt hour meter for class 1 & 2

IEC 62053-21

CBIP Technical report No.88 (with latest amendments)

Specification for AC static Electrical Energy Meters

IS 12063 Specification for degree of protection for enclosure.

IS 5133/1969 (Part II) Specification for boxes for the enclosure of electrical accessories

IS:9000 Basic environmental and other Testing for Electronic & Electrical items.

IS:11731 Specification for engineering plastic 39.3 CLIMATIC CONDITIONS:

The meters to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot, cold, tropical and dusty climate and solar radiation typically existing in state of M.P. The meter shall be required to operate satisfactorily and continuously under the following tropical climatic conditions:

(a) Maximum ambient air temperature 55oC (b) Maximum ambient air temperature in shade 45oC (c ) Maximum temperature attainable by the meter exposed to

sun 60oC

(d) Minimum ambient temperature (-) 5oC (e) Average daily ambient air temperature 40oC (f) Maximum relative humidity 95% (g) Number of months of tropical monsoon condition 4 months (h) Maximum altitude above mean sea level 1000 meters (i) Average annual rain fall 150 cms (j) Maximum wind pressure 200 kg/sq.m (k) Isoceraunic level (days per year) 40 (l) Seismic level (horizontal accn.) 0.30 g (m) Permitted noise level 45.db



39.4 TECHNICAL REQUIREMENT & DESIGN CRITERION Meters are required for installation in the premises of LT consumers. The basic system

parameters wherein these meters will be installed shall be as under:-

Sl.No. Item Specification 1. Type of installation Indoor/Outdoor 2. System voltage (phase to neutral) 3x240V + 20% to - 40% three phase 3. System frequency 50 Hz ±5% 4. No. of phases 3 phase 4 wire 5. System earthing Solidly grounded 6. Resistance to surge voltage of 1.2/50

Micro sec. 6 KV peak

7. Test voltage at 50 Hz 2 KV RMS for 1 minute

The meter shall be 3 phase 4 wire type, suitable for continuously 240 VAC (Phase to Neutral) and shall be capable of withstanding twice the nominal voltage between phase to neutral (or earth) for short duration.

39.5 POWER CONSUMPTION Voltage Circuit: The active and apparent power consumption in each voltage circuit (per

phase) including power supply of meter at reference voltage, reference temperature and reference frequency shall not exceed 2 Watts and 10 VA respectively.

Current Circuit: The apparent power taken by each current circuit (per phase) at basic current, reference frequency and reference temperature shall not exceed 4 VA as per IS:13779.

Auxiliary Power: The meter shall draw power for working of electronic circuit from phase & neutral.

STARTING CURRENT:

The meter should start registering energy at 0.4% of basic current at UPF as per IS:13779. RUNNING WITH NO LOAD:

When 115% of rated voltage is applied with no current flowing in current circuit, the test output of the meter shall not produce more than one output pulse count as per IS:13779.

RADIO INTERFERENCE SUPPRESSION AND ELECTROMAGNETIC CAPABILITY:

The meter shall not generate, conduct or radiated noise, which would interface with the other requirement. The above shall conform to the requirement listed in the applicable standards.

The meters shall work satisfactorily in the absence of neutral and shall work even if any two

voltage wires are extended to the meter. Meter shall have facility to allow downloading of selective data at faster speed to save the time

while reading the meter for billing purpose through AMR or MRI. The downloading of billing data should be possible in less than 3 minutes.

Overall Accuracy offered to the system shall be – Class 1.0 39.6 SALIENT FEATURES The meters shall make use of Non Volatile Memory capable of storing & retaining all the

data required to be stored, without the help of any power source or battery back up.

Computation of demand shall be on the basis of Real Time Clock of the meter itself.

Provision shall be there to do the billing operation automatically at a predefined date by programming the meter. If required, billing shall also be possible with the press of MD reset button.

Meters covered under this specification shall be fully static type with non-volatile memory to register various billing parameters and complete with other features as detailed out in this specification. Any other design meeting technical specification or features/accuracy etc., better than this specification and manufactured as per relevant IEC/IS/CBIP report shall also be acceptable.



Meters shall be suitable for accurate measurement and display of energy and other billing parameters within the specified limits of errors under balanced and unbalanced load conditions in a poly phase network.

Indications shall be provided on display to show the healthiness of phase voltage.

The meter shall be fully programmable by the user for TOD timings and billing dates etc. For security reasons, the meter operating software should have at least “two level write protection” against any modification/editing of the parameters, data, settings etc. except those required for Billing data, TOD metering.

The meter shall conform to the degree of protection IP 54 of IS: 12063/IEC: 529 for protection against ingress of dust, moisture and vermin’s.

The meter-base & meter-cover shall be made of high grade, fire- resistant, non-inflammable, high-grade and good quality engineering plastic.

The meter shall have provision in such a way that outgoing cable of transformer shall be directly passed through the meter for measurement. Piercing screws shall be used in the meter for voltage connection.

The meter shall be suitable to accommodate aluminum cable of 100A current carrying capacity.

The meter connection arrangement should be such that so there is no need to remove insulation for connecting cable for current measurement. Design should support thread through concept where connecting cable directly passed through the meter for measurement.

As the cable directly passed through the meter, the offered meter should not have provision for meter terminal connection as well as terminal block.

The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling during transportation. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling.

39.7 POWER FACTOR RANGE: The meters shall be capable to record over full power factor range of Zero Lag-Unity- Zero Lead. However for specified accuracy the power factor range shall be as per IS.

39.8 CALIBRATION, CONFIGURATION & PROGRAMMING

The Meter should be only factory calibrated, configured and programmed. No device, such as potentiometers shall be used which can result in change of calibration at site.

The above activities should not be possible at site through the use of user software or any such means. It shall, however, be possible to check the accuracy in the field by means of the test output. No setting points/setting registers etc. shall be provided for adjustment of measurement errors. Once finalised, the meter constants shall be freezed and it shall not be possible by the manufacturer or the user to alter the meter constants either at factory or at site.

Provision shall be made to read various billing parameters and tamper data recorded by

meter through a meter reading instrument. This arrangement can be through an optical port. Provision shall be made to seal the optical port to ensure proper security.

39.9 DISPLAY:

The meters shall have bright LCD Electronic display with backlit & with minimum 7 digits to read up to one tenth of KWh with another digit for legend. The decimal digits shall be clearly distinguished from integral digits. The back lit should not glow during power off condition. The LCD shall be of STN (Super Twist Nematic) type designed suitably to withstand temperature of 80oC (storage) & 65oC (operation).

(i) When the meter remains at a constant temperature of 65oC for a period of 30 minutes, the character of LCD should not deform. (ii) After keeping the meter at a constant temperature of 80oC for a period of 30 minutes and when restores at normal temperature, LCD display should work as in normal conditions. The LCD display should have a wide viewing angle of 45oC to 60oC and up to one-meter distance, for clear visibility of the display of the meter reading. Large viewing area with large display icons is preferred. There shall be 7 segments 7 digits for display of parameters value.



The registered parameters shall not be affected by loss of power. The display shall not be affected by electrical and magnetic disturbances. The meter shall make use of non-volatile memory capable of storing and retaining all the data required to be stored, without the help of any power source or battery back up and shall have a minimum retention time of 12 years under un-powered condition. The minimum character height X width shall be 10 X 5 mm. The accuracy of display parameters for all parameters shall be matching with the accuracy class of meter as per IS.

The display of various parameters shall be scrolling one after another. The display shall

have ON time of at least 10 seconds for each measured value. 39.10 DISPLAY PARAMTERS AND SEQUENCE

The meter shall display the required parameters in two different modes as follows:- a) General Requirements

(I) Auto display mode i) Date DD:MM:YY ii) Time HH:MM iii) Cumulative kWh iv) MD KW/KVA v) Instantaneous P.F with sign of Lag / lead vi) Average power factor of the last month vii) Main Billing active KWh viii) TOD 1,2,--,6 Billing active KWh ix) Billing MD kW/KVA

(II) Display Parameter Push Button mode

The display of the following parameters shall be continuously scrolling one after another through push button. The display shall have ‘ON’ time of at least 10 seconds of each measured value, except LCD segment check. The LCD segment check shall be on meter display for minimum 2 seconds. Display parameters shall move forward if button pressed prior to the programmed time for display of each parameter.

i) LCD segment check ii) Date DD:MM:YY iii) Time HH:MM iv) Rising demand register v) MD reset count vi) Cumulative kWh energy register vii) Cumulative kVArh lag energy register

viii) Cumulative kVArh lead energy register

ix) Cumulative kVAh energy register

x) KW / KVA MD register xi) Cumulative MD register KW/KVA xii) Instantaneous P.F with sign of Lag / lead xiii) Frequency xiv) TOD 1,2,--,6 Cum. KWh xv) TOD 1,2,--,6 Cum. KVAh xvi) TOD 1,2,--,6 MD KW xvii) Average power factor of the last month xviii) Billing MD kW/KVA xix) Billing MD date xx) Billing MD time xxi) TOD 1,2,--,6 Billing MD registers xxii) Main Billing KWh register xxiii) TOD 1,2,--,6 Billing KWh registers xxiv) Main Billing KVAh register xxv) TOD 1,2,--,6 Billing KVAh registers xxvi) Tamper information-This shall be displayed when tampered with following.

a) Date of last tamper occurrence b) Time of last tamper occurrence c) Number of times meter tampered

b) Programmable Optional Requirements:

i) Phase wise current - A



ii) Phase wise Voltage - V iii) Instantaneous Power - KW/ KVA

c) View Parameters:(Information required through meter reading instrument on BCS)

i. Phase wise current - A ii. Phase wise voltage - V iii. Active energy - KWh iv. Reactive energy lag - KVArh lag v. Reactive energy lead - KVArh lead vi. Apparent energy - KVAh vii. MD during the month - KW/ KVA viii. Avg. P.F. of last 3 months - - ix. Tamper information - x. Present demand - KW/ KVA xi. Instantaneous Power factor - In two digit with indication of lag/lead xii. Load survey - - xiii. All balance parameters of (a) and (b) above

39.11 METER READING AT POWER OUTAGE:

Provision to read the meter in no power condition shall be made. The same push button shall be used for display the auto scroll mode during power outage. A suitable internal/ external device could be used so that display of readings could be possible at least twice considering that continuous power outage will not be for a period of exceeding 24 Hrs.

39.12 MAXIMUM DEMAND REGISTRATION

Maximum demand computation shall be updated based on sliding window principle only and demand integration period of 15 minutes programmable with updates of 5 minutes for 15 minutes IP. The meter shall monitor during each integration period of the month & display maximum value occurred.

The MD integration cycle shall be on the basis of real time. However, the real time clock of the meter shall be used only for the purpose of time matching and for computation of maximum

demand the internal clock of meter shall be made use of. 39.13 BILLING REGISTERS/ MD RESET:

Each register shall have an associated billing register. When a billing operation occurs, the contents of the rate registers shall be transferred to there billing equivalents. The meter shall display the maximum demand reset count. Billing operation may be caused by any of the following means:

Automatic Billing

Automatic billing operation shall also be supported. On user specified/programmed day

the billing operation shall occur at 00:00 hrs.

Manual Billing

The left-hand button on the front of the meter shall be capable of reset maximum demand. Pressing the left-hand button shall then cause a billing operation, which includes resetting any maximum demand registers that are in operation.

Only one manual billing operation shall be possible in any given 15 minutes. Subsequent presses of the MD reset button shall be ignored if a manual billing operation has already occurred within 15 minutes.

Electronic Billing

Sending a secure MD reset message to meter via the optical port shall cause a billing operation. Normally this option shall be disabled.

39.14 CUMULATIVE DEMAND REGISTERS

The cumulative demand registers keep a running total of the value of maximum demand registers, and are updated each time billing occurs.



39.15 LOAD SURVEY The meter shall have non-volatile memory for recording load survey for KW or KVA (programmable). The load survey data shall be logged for last minimum 35 days for interval of 15 minutes.

39.16 TAMPER FEATURES

a. The following tamper information shall be available in the meters to detect common ways of tamper & fraud.

i) Missing potential detection: The meter shall detect Potential missing and record this information along with date & time of occurrence and restoration of the event and phase indication.

ii) CT reversal Detection: The meters shall detect and indicate the occurrence of CT reversal on meters display along with phase indication and shall also store the date & time of occurrence and restoration in the non-volatile memory. Even if meter detects such a condition, the recording of KWh shall be done in positive direction only.

iii) Current Imbalance (CT shorting/by-passing): In case of CT open or shorting, which may result in the current imbalance between the phases, the tamper indication should appear by means of measuring neutral current.

iv) Voltage Unbalance: The meter shall be capable of detecting and recording occurrences and restoration of voltage unbalance as an event.

v) Power ON/OFF: Meter shall be capable of detecting and recording power off of all voltages not present. The event shall be recorded on the next power up. At the same time, power on event shall be recorded.

b. External Magnetic Influence: The meter shall not get influenced by any external magnetic fields (AC Electro Magnet or DC Magnet) as per value(s) specified in IS:13779 with its latest amendment for AC Magnetic Field. However, the meter alone should comply up to 0.27 Tesla DC. The meter accuracy or accuracy in display under normal conditions shall not be affected by placement of a permanent magnet of 0.27 Tesla ± 5%, anywhere on the surface of meter without meter box.

On application of external DC and AC magnetic field of higher intensity (abnormal magnetic induction) against which meter is not immune, the meter should log the events of abnormal magnetic induction with date and time. The positive error may be beyond the limit of 4% but not exceeding power value equivalent to the product of rated voltage and maximum current.

c. Application of abnormal voltage/frequency:

(I) The accuracy of the meter, Real time clock disturb, Memory data corruption, meter functioning hang up etc. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0.01-10 mm spark gap in any of the following manner when applied for 10 minutes:

i) On any of the phases or neutral circuit ii) On any connecting wires of the meter iii) At any place in load circuit iv) Spark on meter body.

(II) Meter should also be immune for tamper by application of remote loop induction device (jammer).

When meter is subjected to 35 KV abnormal voltage, frequency burst and remote loop induction device (jammer), it should not hang and in case it hangs once it should remain hanged permanently.

d. Along with the information, the meter shall also record the instantaneous values of all three-phase voltages, three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events.

e. The meter shall record min. 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. The event recording shall be compartment-wise roll over type i.e. it shall always maintain record of last 200 events occurred.



f. Phase Sequence Reversal: Meter shall operate and record satisfactorily irrespective of phase sequence of input supply so long as phase association between voltage and current circuits is in order.

g. Neutral Missing: The meters shall work properly even if neutral is not available and shall work satisfactorily even if any two of potential wires are extended to it.

h. Logics for design of above indicated tamper, the value of voltage, current, time etc. to be selected for design of tamper logics shall be in consultation with the purchaser. (The last tamper event as per above tamper is to be included in the DISPLAY and rest of the details in VIEW PARAMETERS).

Provision shall be made for push button to initiate display parameter in the front of the meter.

Provision shall be made for maximum demand (MD) reset push button with provision of sealing.

An operation indicator in the form of blinking visible signal shall be provided to indicate that the meter is operating satisfactorily. Manufacturer may confirm whether the blinking visible signal is of weighted pulse and this can be effectively used for verification of accuracy.

Tamper information shall remain on display, unless authentic command is received.

Note : 1. The meter shall not get affected by any remote device. 2. The manufacturer should furnish detailed explanation as to how the meter is able to detect/

protect recording the above tamper and fraud features with sketches and phaser diagram. Additional features, if any, in the meter may also be clearly indicated.

39.17 BILLING POINT REQUIREMENTS:

The predefined date and time for registering the billing parameters of kWh, PF and KW/kVA MD as well as Tamper Count and Power-On hours readings shall be at 00.00 hours of the first day of each calendar (billing) month. All billing parameters shall be transferred to billing registers and shall be displayed on auto cyclic display mode referred to as "BILLING PARAMETERS".

The above billing data, TOD register's data, load survey data, tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details.

Further, apart from instantaneous parameters like voltage, current, PF, and readings of billing parameters, energy registers, TOD registers etc., the following additional parameters should be made available at the BCS end:

a) MD reset count. b) Billing Parameters for last 6 Histories.

39.18 PERFORMANCE ON DC INJECTION: - Apart from all the technical requirements as specified above, it should also be ensured that meter should not stop and record consumption accurately even on injection of DC voltage in neutral.

39.19 TOD TARIFF/DEMAND

The meter should be capable of registering the time-of-day energy and maximum demand. The time zones shall be provided at the time of ordering.

The meter should have in-built capacity to define up to six time zones. The change of the TOD time-period(s) or defining additional TOD zones should be possible through CMRI with special authenticated command from the BCS so that only authorized person(s) can make such changes. The main control of this system along with proper security password/code should be available on one or more computers located at the authorized location(s) as per the directions to be given by the Purchaser.



Provision should be made for automatic reset of maximum demand at the end of pre-defined period (e.g. end of the month). The billing parameter at the time of automatic reset of the maximum demand shall be programmable. In addition reset of maximum demand shall be possible through push button or through a hand held terminal capable of communicating with the meter.

In every case the design shall include provision of updating of cumulative demand register with updating of reset counter.

Necessary compatible meter application software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above shall be provided by the supplier. No separate cost will be borne by the purchaser on this account.

39.20 DATA SECURITY:

The data transfer from the meter to MRI and MRI to computer should be fully secured and any unauthorized change in data should be indicated on computer system. There should be multi level password on the base computer system and in the meter to prevent any unauthorized change of TOD timings or resetting of demand, reading of meter etc.

39.21 A suitable battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition. The information of meter including integration etc. shall be independent of requirement of battery. The minimum life of lithium battery should be seven years.

Under battery weak condition, an indication shall appear on the BCS display. 39.22 OUTPUT DEVICE:

The meters shall have a test out put in the form of a blinking LED for testing of the meters accuracy. Testing shall also be possible through optical port accessible from the front and can be monitored with Meter Reading Instrument having high-resolution display. The meters shall give high-resolution energy values directly to meter reading instrument. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time.

39.23 COMMUNICATION CAPABILITY:

(a) The meters shall have galvanically isolated optical communication port so that it can be easily connected to hand held common meter reading instrument for data transfer. The optical port shall be located in the front of the meter & shall have adequate sealing arrangement to seal it. Serial communication Protocol shall be adopted for data communication.

(b) Remote communication mode for data retrieval: The meters would be mounted at height on the secondary of distribution transformers and it is difficult to take meter readings at height therefore reading of meter should be taken by choosing any one of the following means:

(i) Through GSM Modem: The GSM Modem shall be provided with store and forward feature in the same enclosure of meter. Modem shall be connected such that the galvanically isolated port of meter shall be free for the data downloading through CMRI. The specification of modem is as per subsequent paras.

(ii) Optical port of the meter shall be extended suitably downwards, 1.5 meters above the ground level such that meter could be read easily through the MRI. Extended port shall be robust & well protected with locking and sealing arrangement.

(c) Meter Reading Instrument (MRI):

i. The MRI suitable for reading shall be supplied in the ratio of one for each 300 nos. of meters free of cost along with battery charger.



ii. The MRI shall have facility to store minimum 100 nos. of meter’s data. Further, there should be a facility in MRI to provide the transfer of meter data to computer through RS 232 or USB port.

iii. The MRI shall be capable for down loading readings of other makes of meters. The bidder shall give an undertaking to this effect

It shall be responsibility of the meter manufacturer to provide the required software and all the facilities required by the purchaser, to use the MRI for reading and retrieving the data from the meter and to download the data to Base Computer free of cost till the expiry of guarantee period.

39.24 BASE COMPUTER APPLICATION SOFTWARE

For efficient and speedy recovery of data read through AMR/CMRI/HHU, Base computer software shall be supplied having the following specifications as below:

The BCS software shall be user friendly. Windows based Base computer software shall be supplied. Base Computer software shall give all details adequate for analysis and load surveys parameters. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. EDP department of purchaser can generate its own DBF (data base files) to downloaded all the required information into it.

ix. Platform: The BCS shall be executable on all WINDOWS system. The BCS shall be suitable to run on IBM compatible PC hardware platform.

x. Meter Data Display:The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram)

All the information about energy, maximum demand and their respective TOD register reading, billing register readings shall be shown in a manner which user can easily understand.

All the load survey data shall be available in numerical as well as graphical format. It shall be possible to view this data daily, weekly, and monthly format. The load survey graph will show values where the cursor is placed for the selected or for all parameter.

All the information about abnormality events shall be accompanied with date and time stamping along with 'snap-shot' of respective electrical conditions. This information shall be displayed in the sequence in which it happened in cumulative format as well as summary format.


xi. Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. All information about a particular consumer will be sorted out and available at one place so that locating any consumer 's past data is easy. It shall be possible to retrieve/locate data on the basis of either one of the following particulars:

e) Consumer's ID/Numbers. f) Meter Sr. No. g) Date of meter reading. h) Location.

xii. The Data Transfer: It shall be possible to transfer data to and fro from CMRI through serial interface.

xiii. Configurability: It shall be possible to have selective printing of all available data of the meter. Print out shall not include anything and everything available with the BCS. The software shall support "print wizard" whereby user can decide what to print out. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires.


xiv. Security:The BCS shall have multilevel password for data protection and security. The first level shall allow the user to enter the system. The different software features shall be protecting by different passwords. The configurable of passwords shall be user definable. The software installed on one PC shall not be copiable on another PC.



xv. BCS shall have feature to read data through AMR in different modes through GSM/ GPRS infrastructure.

xvi. Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents.

39.25 APPLICATION PROGRAMME INTERFACE (API)

The bidder shall provide Application Programme Interface (API) to read their meters and convert the meter data as per IEEMA MIOS standard. Supply of API with the meter is mandatory.

39.26 CONSTRUCTION OF THE METER

The components on the PCB shall be of surface mounted to ensure reliable performance even under shock/vibration.

Body of the meter shall be designed suitable for projection mounting. The meter should be made of high quality raw materials to ensure higher reliability and longer life. The meter should be compact and reliable in design e.g. to transport and immune to vibration and shocks involved in transportation/ handling. The construction of the meter shall be suitable for its purpose in all respects and shall give assurance of stable and consistent performance under all conditions especially during dust storms/heavy rains/very hot days. The meter shall conform to the degree of protection IP 54 of IS: 12063/IEC: 529 for protection against ingress of dust, moisture and vermin’s.

All insulating material used in the construction of the meter shall be non-hygroscopic non ageing and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion. The construction of the meter shall be such as to be sealed independently and prevent unauthorised tampering.

Meters described above shall be installed out door, directly under the sun and extreme weather conditions. Suitability of such use shall also be confirmed.

39.27 METER CASE AND FRONT DOOR:

The meter shall have a case, which should be sealed in such a way that the internal parts of the meter are not accessible unless body is broken. Minimum three sets of seals i.e. for Piercing screws, meter cover and the front door shall be provided. The meter shall be made of self extinguishing polycarbonate/Engineering Plastic. The case shall be so constructed that any temporary deformation may not effect the satisfactory operation of the meter. The meter unit shall have opaque front hinged door with suitable sealing arrangement (screws). The

front door shall be sealed independently & over the terminal cover. Approach to the MD reset button,

reading button and optical port shall only be possible after opening the front cover.

38.28 TERMINAL (PIERCING SCREW) COVER:

The PT Piercing screw cover for the meter shall be extended type, which can be sealed independently & over the meter cover. The PT terminals shall not be accessible without removing the seals of the terminal cover when energy meter is mounted on the meter board/ wall.

39.29 MOUNTING ARRANGEMENT

Suitable wall mounting arrangement for the complete meter unit shall be provided such that the mounting bolts shall be operated/ opened or accessible only after operation of a set of seal. Proper locking arrangement shall be provided to protect from unauthorised removal of meter from its mount.

39.30 INSULATION:

The meter shall have durable and substantially continuous enclosure made of wholly insulating material, including the terminal cover, which envelops all metal parts with the exception of small parts and should withstand an insulation test at 4 KV.

39.31 RESISTANCE TO HEAT AND FIRE:

The terminal block and the meter case shall ensure reasonable safety against the spread of fire. These should not be ignited by thermal overload of live parts in contact with them.



(a) SEALING OF THE METER:

The meter body shall be provided with 2 nos. polycarbonate tamper evident seals having 6 digit serial no. The nos. of the seal shall be unique and should not be repeated in any case. All the seals should be provided on front side only. Access to the working part should not be possible without breaking the seals. Provision of at least 2nos. seals on front door, 1 no. seal each on maximum demand device and communication port, 2nos. seals on the terminal cover shall also be made. Rear side sealing arrangement is not acceptable.

The polycarbonate seals shall have proper locking to avoid opening of the seal in any case by means of tampering.

(b) TRACKING SOFTWARE FOR SEALS:

It is mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing, procurement, storage, record keeping, installation, series of inspections, removal and disposal etc.

39.32 CONNECTION DIAGRAM & TERMINAL MARKINGS:

The connection diagram of the meter shall be clearly shown on inside portion of terminal cover & shall be of permanent nature. Meter terminals shall also be marked & this marking should appear in the above diagram.

39.33INSTALLATION CHECK:

While installing the meter, it shall be possible to check the correctness of the connection to the meters and there polarity from the functioning of the meter with the help of CMRI under load condition. The phase sequence and phased association of voltage and current can be checked with the help of CMRI.

39.34 GUARANTEED TECHNICAL PARTICULARS:

The bidder shall furnish all the necessary information as desired in the Schedule of Guaranteed Technical Particulars and data, appended with this Specification. If the bidder desires to furnish any other information(s) in addition to the details as asked for, the same may be furnished against the last item of that Annexure.

39.35TECHNICAL DEVIATIONS:

Any deviation in Technical Specification as specified in the Specification shall be specifically and clearly indicated.

39.36 NAME PLATE AND MARKING:

Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with relevant standard (latest version). The following information should appear on the name plate affixed on to the meter:- (i) Manufacturer’s name or trade-mark and place of manufacture. (ii) Designation of type (iii) Number of phases and number of wires for which the meter is suitable. (iv) Guarantee period – 5-1/2 years. (v) Purchase Order No. & Date. (vi) Property of MPEZ. (vii) Bar coding of SN, Month & Year of manufacture (viii) Sign of Insulation Class (ix) Serial number, year and month of manufacture (x) Principal unit in which the meter records (xi) Reference voltage (xii) Basic current and rated maximum current (xiii) Reference frequency in Hz (xiv) Meter constant (xv) Accuracy class (xvi) Reference temperature (xvii) ISI mark and licence number

39.37 TESTS:

a. Type Test :



Meter shall be type tested as per relevant standards (with latest amendments). Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test.

b. Acceptance tests : All Acceptance tests as laid down in Indian Standards shall be carried out. The accuracy of display parameters shall be verified at the time of inspection in line with class of accuracy of meter.

c. Routine Tests: All the routine tests as stipulated in relevant standards in addition tamper and fraud protection tests as per clause-22 shall be carried out and test certificates shall be furnished for approval of the purchaser.

39.38 TEST FACILITIES:

a) The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials.

NOTE: The standard meters used for conducting tests shall be calibrated periodically at

reputed Government Accredited Test Laboratories and test certificates shall be available at Works for verification by purchaser’s representative.

b) The manufacturer shall have at least the following testing facilities to ensure accurate calibration :- (i) Insulation resistance measurement (ii) Running at no load (iii) Starting current test (iv) Limits of error (v) Range of adjustment (vi) Power loss in voltage and current circuit (vii) Repeatability of error (viii) Transportation test (ix) Low load run test (x) Heating test

c) Routine Test:

Each and every meter of the offered lot shall undergo the routine tests as well as functional tests as per relevant standards, routine test report of all the meters of offered lot shall be handed over to the Inspecting Officer prior to carrying out the acceptance test.

39.39 INSPECTION :

a. The purchaser reserves the right to get type tests done in respect of any meter, or Box from any of the lots received at any Destination Stores at supplier’s expenses.

39.40 RANDOM SAMPLE TESTING AFTER RECEIPT AT STORES:

The consignment of meters received at Area Stores shall be accepted only after acceptance test of meters at CPRI/ERDA or any NABL accredited lab. Some sample of meters shall be selected randomly from a lot of meters supplied and sent to CPRI for acceptance test as per relevant ISS and as per procedure prescribed in following paras. If the sample fails in the above tests, the entire lot will be rejected and testing charges shall be recovered from the supplier.

39.41 QUALITY ASSURANCE PLAN:

The designed life of the meter shall be minimum 20 years and to prove the designed life, the firm shall have at least the following Quality Assurance Plan:-

(i) The factory shall be completely dust proof.

(ii) The testing rooms shall be temperature and humidity controlled as per relevant standards.

(iii) The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates.



(iv) Power supplies used in testing equipment shall be distortion free with sinusoidal, wave- forms and maintaining constant voltage, current and frequency as per the relevant standards.

(v) During the manufacturing of the meters the following checks shall be carried out.

(a) Meter frame dimensions.

(b) The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated.

(c) The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any possibility of human errors.

The Bidder shall invariably furnish the following information along with his bid, failing which his bid shall be liable for rejection. Information shall be separately given for individual type of material offered.

(i) Statement giving list of important raw materials, names of sub-suppliers for the raw

materials, list of standards according to which the raw materials are tested, list of tests normally carried out on raw material in presence of bidder’s representative and copies of test certificates.

(ii) Information and copies of test certificates as in (i) above in respect of bought out accessories.

(iii) List of manufacturing facilities available.

(iv) Level of automation achieved and list of areas where manual processing exists.

(v) List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.

(vi) List of testing equipments available with the bidder for final testing of equipment specified and test-plant limitations, if any, vis-à-vis type, special acceptance and routine tests specified in the relevant standards and this specification. These limitations shall be very clearly brought out in schedule of deviations.

(vii) The manufacturer’s laboratory must be well equipped for testing of the meters. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document.

39.42 MANUFACTURING ACTIVITIES:

(i) All the materials, electronics and electrical components, ICs used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability, longer life and sustained accuracy.

(ii) The manufacturer should use Application Specific Integrated Circuit ASIC or Micro controller for metering functions.

(iii) The electronic components shall be mounted on the printed circuit board using latest Surface Mounted Technology (SMT) except power components by deploying automatic SMT pick and place machine and re-flow solder process. The electronic components used in the meter shall be of high quality. Further, the Bidder should own or have assured access (through hire, lease or sub-contract) of the above mentioned facilities. The PCB material should be of glass epoxy FR-4 grade conforming to relevant standards.

(iv) All insulating materials used in the construction of meters shall be non-hygroscopic, non-aging and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating.

(v) Quality should be ensured at the following stages:

(a) At PCB manufacturing stage, each board shall be subjected to bare board testing. (b) At insertion stage, all components should undergo testing for conforming to design

parameters and orientation. (c) Complete assembled and soldered PCB should undergo functional testing using test

equipments (testing zig).



(d) Prior to final testing and calibration, all meters shall be subjected to accelerated ageing test to eliminate infant mortality.

(vi) The calibration of meters shall be done in-house.

39.43 DOCUMENTATION :

a. All drawings shall conform to International Standards Organization (ISO “A” series of drawing sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units.

b. List of drawings and documents: The manufacturer shall furnish the following.

(i) Two sets of drawing clearly indicating the general arrangements, fitting details, electrical connections etc.

(ii) Technical leaflets (user’s manual) giving operating instructions.

(iii) Three copies of dimensional drawings of the equipments.

c. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawing shall be at the supplier’s risk.

d. Approval of drawings by purchaser shall not absolve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respect to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have the power to reject the materials which, in his judgement, is not fully in accordance therewith.

e. The manufacturer within 2 weeks of notification of award of contract, submit three sets of final versions of all the drawings as stipulated in the purchase order for purchaser’s approval. The purchaser shall communicate his comments/ approval on the drawings to the supplier within two weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for approval. The supplier shall within two weeks, submit 10 prints and two good quality report copies of the approved drawings for purchaser’s use .

f. Ten sets of operating manuals/technical leaflets shall be supplied to each consignee for the first instance of supply.

g. One set of routine test certificates shall accompany each dispatch consignment.

h. The acceptance test certificates in case of pre-dispatch inspection or routine test certificates in cases where inspection is waived shall be got approved by the purchaser.

39.44 GUARANTEE :

(i) Defect Liability period shall as per clause GCC 27.10 of SCC Section 8 of the Bid document.

39.45 PACKING & FORWARDING:

a) The equipment shall be packed in crates/boxes suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Any material found short inside the packing cases shall be supplied immediately by supplier without any extra cost.

b) Each consignment shall be accompanied with a detailed list containing the following information. i) Name of the consignee



ii) Details of consignment iii) Destination iv) Total weight of consignment v) Handling and packing instruction vi) Bill of material indicating contents of each package vii) The packing shall be done as per the manufacturer’s standard practice. However, he

should ensure the packing is such that the material should not get damaged during transit.

39.46 TECHNICAL SPECIFICATION OF GSM MODEM

The modem shall be built in the meter enclosure and connected internally. The system shall be used for remote meter reading of the consumer meters via GSM infrastructure. The communication and reading shall be enabled with suitable Base Computer Software (BCS). The modem shall offer in-built intelligence and high speed data transfer rate or a kind of store-forward facility by which data from the meter is read at regular intervals and stored in modem’s internal memory and forwarded to remote central station (as configured) for viewing billing and reporting via Base Computer Software.

Various features of GSM modem (to be installed with electronic energy meter) are described as below:

39.46 (a) Power Supply Section

Input supply

d. The modem shall be powered up with the meter itself. e. Average Power consumption of the modem shall be 3 VA under idle condition

and 6 VA during data transfer. Note: Power consumption may vary from site to site depending on signal strength at

that particular location. Above values are typical values.

Withstand capacity against surges should be according to Indian conditions i.e. 6.0 kV.

The modem shall have capability to work under continuous power on condition.

39.47 GSM Section:

The GSM module shall comply with the following:

The modem shall operate in GSM 900/1800/1900 MHz Band.

The modem shall be compliant with ETSI GSM Phase 2+ Standard.

Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800/1900 MHz

The modem shall support Point-to-Point transmission and Cell Broadcast features.

It shall have auto dial feature.

SIM Card Section For placing the SIM Card, a SIM Card Holder shall be provided on the GSM motherboard and shall be accessible only by removing the sealable cover.

The SIM Card shall be of 3V Interface.

Interlocking facility shall be provided under the device cover.

RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band Antenna can be connected. The antenna should be of minimum 3dbi gain.

Provision shall also be made to connect 14db high gain external yagi antenna to improve poor signal strength.

Network Identification Section For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data).

39.48 EMI/EMC Specifications

The GSM modem shall meet the following EMI/EMC specifications: 38.3 Electrostatic Discharge IEC61000-4-2



38.4 Fast Transient Burst IEC61000-4-4 38.5 Surges Immunity IEC61000-4-5

(Under Line to Earth & Line to Line immunity) 38.6 Conducted Emission CISPR22 (class B)

39.49 Mechanical Specifications

The Mechanical Specifications of the modem shall be as follows: a. Modem shall be located in meter enclosure such that it has separate sealable

opening. b. The portion of the meter where modem is placed shall have a suitable sealing

arrangement so that the GSM SIM Card cannot be tampered with.

39.50 Environmental specifications

The modem shall meet the following environmental specifications: Temperature: -10 degrees to +55 degree Humidity: - 95% RH (non – condensing)

39.51 Functional specifications

The modem should be an intelligent device and capable of providing the following functionalities:

39.52 Inbound dialing

a) The modem should have inbound dialing facility ie. modem shall automatically dial to a particular GSM number (number of modem placed at central station end along with BCS server) at specified time (once in a day/week/month) for the purpose of meter reading. This configuration of the modem shall be made available to the user via offered Base Computer Software. b) If modem at consumer end could not establish connection to the modem at central station at specified time, then it shall retry the same as configured.

39.53 Outbound Dialling

(a) In case the data is required by dialing from the Central station end (Server end), then connection shall be established by the server to the device using AT commands and transparent communication mode shall be established.

(b) User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem.

39.54 Event based dialing

(a) Other than regular dialing, the modem shall have feature of event based dialling in case of logging of tamper by the meter, without waiting for the interrogation from central station (BCS server) and meter data shall be sent to the central station

(b) Further, the modem shall sent an SMS to predefined mobile number and the SMS shall contain meter serial no. The mobile number shall be configurable via BCS.

(c) Event based dialing and SMS shall be applicable for the event types (tamper/anomally) as supported/recorded by the meter

(d) When the modem is busy in collecting the data from the meter and the call comes to get the data, then priority shall be given to outbound call rather than data collection from meter.

(e) The feature of event based dialing shall be user configurable. Provision of enabling and disabling of the feature shall be provided

39.55 VERIFICATION/TESTING OF MATERIAL SUPPLIED

a) Type test Three (3) samples for Type Test shall be selected & sealed by authorised person of MPPKVVCL from the first lot received in contractor’s site stores. The selected samples shall be sent with complete details for type test at CPRI / ERDA / any NABL accredited test house. The type test charges shall be borne by the supplier.



In case of successful type test results, supplies shall be continued. However, in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s), three more samples shall be selected from the supplies already received to get them type tested at contractor’s cost. In case of repeat failure in type test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled.

d) Acceptance test v) On receipt of subsequent consignment of individual DI in contractor’s site Stores, set

of meters as per relevant standards shall be selected randomly and sent to CPRI/ERDA for conducting acceptance test as per the prescribed procedure.

vi) In case of failure of samples of lot/ sub-lot in the test(s) detailed in ISS, the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the contractor at his own cost. Repeated failure/poor results in the testing may render cancellation of order.

vii) The supplies, at the option of employer, may be utilized in the field during the period of testing. In case of repeat failure in acceptance test(s), the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost.

viii) The employer also reserves the right to get additional samples for all or any of the selected tests at purchaser's cost at any independent test house at any stage of supply, if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. In case of failure, the guarantee period of the quantity already supplied by the contractor shall be doubled and employer reserves the right to cancel the balance quantity.

e) In case of failure in type test or acceptance test, employer may allow the contractor to re-offer the material after change/ modification in the design of meters. The balance material shall be accepted only after successful Testing. The Testing charges shall be borne by the contractor.

39.56 GUARANTEED TECHNICAL PARTICULARS FOR 3 PHASE 4 WIRE AC STATIC TRIVECTOR ENERGY METERS FOR DTR

S N

Particulars Minimum requirement Offered

1 Name of manufacturer To be mentioned

2 Model To specify

3 Standard Applicable IS:13779/ CBIP report 88 with latest amendment

4 Rating

(i) Accuracy class Class -1.0

(ii) Rated voltage 3X240 V, +20% -40%

(iii) Rated current Ib-40 Amps, Imax-100 Amps

(iv) Rated frequency 50 Hz ± 5%

(v) Power factor 0 lag to unity to 0 lead

(vi)Magnetic immunity As per CBIP-88 with latest amendments

5 (i) Continuous current rating 100 Amps

(ii) Running with no load & 115% rated voltage

Should not produce more than one output pulse/count

6 Short time over current 30 Imax for one half-cycle

7 Meter shall start and continue to register at current (unity PF)

0.4 % of Ib

8 Power loss at rated frequency & reference temperature

(i) Current circuit at rated current per phase

Less than 4 VA



S N


(ii) Voltage circuit at rated current per phase

Less than 2 W & 10 VA

9 Momentary over voltage As per relevant standard

10 Dielectric voltage withstand 6 KV AC or as per relevant standard

11 Type of connection The cable directly passes through the meter without any external CTs

It should not be needed to remove insulation of consumer supply cable for current measurement of individual phases

Provision of piercing screw for PT connection should be there.

12 Communication support Galvanically isolated optical port with sealing arrangement

Built in GSM modem with store and forward feature connected internally with the meter with separate port such that optical port shall be free for CMRI communication.

13 Life of RTC Battery specify

14 Type of material used (a) Material

(i) Base High impact strength Engineering plastic

(ii) Meter cover High impact strength flame retardant UV stabilised with window of UV transparent poly carbonate

(iii) Screw Nickel/Tin plated Brass

15 Size of service cable passing Hole

Suitable to accommodate aluminum cable of 100A current carrying capacity

16 Degree of protection Meters shall be installed in consumer premises out door or indoor, directly under the sun and extreme weather conditions. Suitability of such use shall also be confirmed.

Meter shall comply IP 54 of IS:12063/IEC: 529 for protection against ingress of dust, moisture and vermin’s.

17 Type of display LCD

(i) No. of Digits display 7 (One digit after decimal point)

(ii) Character size of display 10x5 mm (Min)

(iii)Operation suitability LCD suitable for operation up to 80

oC

18 Display Sequence ( display should be self explanatory)

18.1 Auto Scroll Mode As per specification

18.2 Push button Mode As per specification

18.3 Programmable Optional Requirements:

As per specification

18.4 View Parameters : (Display/ information required through meter reading instrument on BCS)

As per specification

19.(i) Reading in power off condition

Meter shall be able to display reading.



S N


(ii) Type of arrangement made to display in power off condition

To be explained

20

Maximum Demand Registration

-Computation shall be updated based on sliding window principle only. -Demand integration period of 15 minutes programmable with updates of 5 minutes for 15 minutes IP. -The meter shall monitor during each integration period of the month & display maximum value occurred

21 Billing Registers/ MD Reset: Billing operation may be caused by any of the following means:

Each register shall have an associated billing register. When a billing operation occurs, the contents of the rate registers shall be transferred to there billing equivalents. The meter shall display the maximum demand reset count.

Automatic Billing As per specification

Manual Billing As per specification

Electronic Billing As per specification

22

Cumulative Demand Registers

The cumulative demand registers keep a running total of the value of maximum demand registers, and are updated each time billing occurs.

23 Load Survey The meter shall have non-volatile memory for recording load survey for KW/KVA (programmable). The load survey data shall be logged for last Min. 35 days for interval of 15 min.

24 Downloading of selective data Meter shall have facility to allow downloading of selective data to save the time while reading the meter for billing purpose through MRI/AMR. The time required for selective reading for billing parameter shall be less than 3 Min.

25 BASE COMPUTER APPLICATION SOFTWARE

For efficient and speedy recovery of data read through CMRI/HHU/AMR, and other activity as per TS

26 APPLICATION PROGRAMME INTERFACE

The bidder shall provide application programme interface (API’s) to read their meters and convert the meter data as per IEEMA MIOS standard. Supply of API with the meter is mandatory.

27 METER CASE AND FRONT DOOR:

meter shall have a case, which can be sealed in such a way that the internal parts of the meter are accessible only after breaking minimum three sets of seals, one that of Piercing screw cover, meter cover and the front door

meter unit shall have opaque front hinged door with suitable sealing arrangement (screws).

28 Fixing/ Sealing arrangement



S N


(i) Fixing of meter Suitable wall mounting arrangement for the complete meter unit shall be provided such that the mounting bolts shall be operated/ opened or accessible only after operation of a set of seal. Proper locking arrangement shall be provided to protect from unauthorised removal of meter from its mount.

(ii) Sealing of meter body 2 nos. polycarbonate tamper evident seals or any superior sealing arrangement on front side of meter.

Seals marked with “MPEZ”, company logo and 6 digit serial no. The nos. of the seal shall be unique

Seal shall be provided on front side only.

Meter cover shall be permanently / solidly welded with Base so that it could not be opened without breaking.

(iii) Sealing of front door 2 no. seals front door shall be extended type and can be sealed independently & over the terminal (piercing screw) cover)

(iii) Sealing of maximum demand device

Provision for 1no. seal

(iv) Sealing of communication port

Provision for 1no. seal

(v) Sealing of piercing screw Cover

2nos. seal piercing screw cover shall be extended type and can be sealed independently & over the meter cover)

29 Tracking software mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing, procurement, storage, record keeping, installation, series of inspections, removal and disposal etc.

30 TAMPER FEATURES

(i) Injection of abnormal voltage and frequency of the order of 35 KV with the help of external device

As per TS

(ii) Effect on accuracy of external electromagnetic interference of electrical discharge, external magnetic field & DC current in AC supply or in neutral

As per TS

(iii) Suitability of meter to sustain over voltage i.e phase to phase voltage injected between phase & neutral

Should sustain as per relevant standard

(iv) Missing potential detection: The meter shall detect PT missing and record this information along with date & time of occurrence and restoration of the event and phase indication.



S N


(v) CT reversal Detection: The meters shall detect and indicate the occurrence of CT reversal on meters display along with phase indication and shall also store the date & time of occurrence and restoration in the non-volatile memory. Even if meter detects such a condition, the recording of KWh shall be done in positive direction only.

(vi) Current Imbalance (CT shorting/ by-passing)

In case of CT open or shorting, which may result in the current imbalance between the phases, the tamper indication should appear by means of measuring neutral current.

(vii) Voltage Unbalance:

The meter shall be capable of detecting and recording occurrences and restoration of voltage unbalance as an event.

(viii) Power ON/OFF: Meter shall be capable of detecting and recording power off of all voltages not present. The event shall be recorded on the next power up. At the same time, power on event shall be recorded.

(ix) Neutral Missing: The meters shall work properly even if neutral is not available and shall work satisfactorily even if any two of potential wires are extended to it

(xi) Phase Sequence Reversal Meter shall operate and record satisfactorily irrespective of phase sequence of input supply so long as phase association between voltage and current circuits is in order.

Along with the information, the meter shall also record the instantaneous values of all three-phase voltages, three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events.

The meter shall record 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. The event recording shall be compartment-wise roll over type i.e. it shall always maintain record of last 200 events occurred.

31 Size of calibration LED & colour

As per requirement, preferably red

32 Electromagnetic compatibility EMI/EMC severity level)

Should withstand EMI/EMC level IV

33 Effect of accuracy in tamper condition

Should work within accuracy

34 Input voltage & frequency variation within which meter works satisfactory

+ 20%, - 40% of voltage and ± 5% of 50 Hz

35 Billing Point Requirement As per specification

36 TOD Tariff/Demand

The meter should be capable of registering the time-of-day energy and maximum demand

37 Data Security The data transfer from the meter to MRI and MRI to computer should be fully secured



S N


38 Connection Diagram and terminal Marking:

The connection diagram of the meter shall be clearly shown on meter and shall be of permanent nature. Meter cable passing holes shall also be marked & this marking should appear in the above diagram.

39 Installation Check:

While installing the meter, it shall be possible to check the correctness of the connection to the meters and there polarity from the functioning of the meter with the help of CMRI under load condition. The phase sequence and phased association of voltage and current can be checked with the help of CMRI.

40 Name plate and Marking:

Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with relevant standard (latest version) and as per specification.

41 Drift in accuracy of measurement with time

No Drift in accuracy in measurement with time

42 Fixing arrangement of name plate

Should be secured

43 Type of body Projection type

44 Guaranteed life of meter 5 years from the date of commissioning or 5-1/2 years from date of supply whichever is earlier (shall be printed on name plate of meter)

45 Other parameters / features not covered in the above GTP

Shall conform to Technical specification and IS-13779/ IEC62053-21, IEC62052-11 & CBIP report 88 (Revised version) with its latest amendments



40.0 TECHNICAL SPECIFICATION ‘ISI’ MARKED PVC INSULATE PVC SHEATH

UNARMOURED ALLUMINIUM CABLE 6 SQ. MM.

40.1 SCOPE :-

This specification covers design, manufacturing, testing and delivery of ISI marked 1100 Volt grade,

weather proof unarmoured solid Aluminum conductor, PVC insulated, PVC sheathed Cable 6 sq. mm

suitable for outdoor overhead service lines.

40.2 APPLICABLE STANDARDS:-

All the Cables shall conform to the requirements of following standards with latest amendments, if

any:-

(i) IS:694/1990. - PVC insulated Electric Cables for working voltage up to and including 1100 Volts.

(ii) IS:8130-1984 - Specification for conductor for insulated electric cables. (iii) IS:5831-1984 - Specification for PVC insulation and sheath of electric

cables. (iv) IS:10810-1984 - Methods for test for cables. (v) IS:4905-1968 - Methods for random sampling.

40.3 GENERAL TECHNICAL REQUIREMENT:-

40.3.1 CONDUCTOR: - Aluminum conductor used in cables shall comply to the requirement of

IS: 8130-1984 with latest amendments and shall be in accordance with clauses of relevant ISS of

cables with latest amendments.

40.3.2 PVC INSULATION: - PVC insulation used shall comply to requirement of IS: 5831-1984

with latest amendments.

PVC insulation shall be suitable for continuous conductor temperature of 70ºC under normal

operation and 160º C under short circuit conditions. Insulation shall be of ‘Type A’ PVC compound.

The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be

possible to remove it without damage. The average thickness of insulation shall not be less than

nominal value (ti) specified in relevant ISS. The smallest of the measured values of thickness of

insulation shall not fall below the nominal value (ti in mm) by more than 0.1 mm + 0.1 ti.

40.3.3 SHEATHING: -

The material of the sheath shall be of Type ST-1 PVC compound. The sheath shall be applied

by extrusion over the laid up cores. It shall be so applied that it fits closely on the laid up cores and it

shall be possible to remove it without damage to the insulation. The thickness of extruded sheath and

smallest of the measured value shall conform to the requirement of IS.

40.3.4 OVERALL DIMENSIONS: The mean overall dimensions of the cables shall be as

specified in table-5 of IS:694. The 4 core shall be circular. The difference between maximum and

minimum measured value of overall diameter of sheathed circular cables shall not exceed 15% of the

maximum measured value.

40.3.5 CORE IDENTIFICATION: Core shall be identified by Red & Black colouring of PVC in

accordance with table-7 of IS:694-1990.



40.4 IDENTIFICATION, PACKING & MARKING:

41.4.1 Manufacturer’s Identification:- As per of IS, following marking shall be embossed over

outer sheath at every 3 mtrs.

(a) Cable size and Voltage Grade.

(b) Name of Manufacturer

(b) Word MPEZ.

The embossing & not printing shall be done, automatic in line throughout the length of the

cable and shall be legible and indelible.

40.4.2 Packing & Marking :

(a) The cables shall be supplied in coils of 100 metres each. The packing shall be suitable for

rough handling that is occasioned during transportation.

(b)The cable should carry the following information:-

(i) Reference to Indian Standard (IS)

(ii) Manufacturer’s name, brand name or trade mark

(iii) Type of cable and voltage grade

(iv) Number of cores

(v) Nominal cross-sectional area of the conductor

(vi) Cable code

(vii) Colour of cores

(viii) Length of cable on the reel, drum or coil

(ix) Number of lengths on reel, drum or coil (if more than one)

(x) Direction of rotation of drum by means of an arrow

(xi) Approximate gross weight

(xii) Country of Manufacturer

(xiii) Year of manufacture

(xiv) Word “suitable for outdoor use”

(b) ISI Certification Mark:: The cable must bear ‘ISI’ Certification Mark. In this connection, a

certified photo-stat copy of valid ‘ISI’ Marking License rights duly attested must be submitted

along with the inspection offer as documentary evidence. In absence of ‘ISI’ License

documents, the inspection offer may not be considered.

Standard Length: The standard length of cable shall be 100 mtrs.

40.5 TESTS: Following type tests, acceptance tests and routine tests are to be carried out in

accordance with IS:694/1990 with its latest amendments as indicated below:-

40.5.1 Type Tests: The tests given in Table-8 of IS:694/1990 shall constitute type tests.

40.5.2 Acceptance Tests: The following shall constitute acceptance tests:- Tensile Test (for aluminum, wherever applicable) Wrapping Test (for aluminum, wherever applicable) Conductor resistance test Test for thickness of insulation and sheath Tensile strength and elongation at break of insulation and sheath Insulation resistance test High voltage test at room temperature Flammability test



All the above acceptance tests may be carried out by Discom’s representative as per relevant

ISS at the time of material inspection for the purpose of clearing the lot offered by the

manufacturer. Acceptance test shall be carried out in each type and size of cable selected at

random as per following sampling plan:-

No. of drums/Coils/ No. of drums/Coils/ Permissible number

reels in the lot Reels to be taken as sample of defectives

Upto 25 3 0

26 to 50 5 0

51 to 100 8 0

101 to 300 13 1

301 and above 20 1

40.5.3 Routine Tests: - The following shall constitute routine tests:-

(a) Conductor Resistance test

(b) High voltage test

The above routine tests shall be conducted by the supplier in accordance with relevant ISS

and test certificate in proof of this shall be submitted to this office along with each inspection offer. In

absence of routine test certificate the inspection offer shall be considered as fake and all complication

arising out of this shall be to the supplier’s account.

40.6 IMPORTANT TECHNICAL REQUIREMENT

Cables shall be designed to withstand mechanical electrical and thermal stress developed under steady

state and transient operating conditions.

40.7 TYPE TEST CERTIFICATE:

The certified photo copy of type test certificates in respect of each size of cables for type tests

given in Table-8 of IS:694/1990 from the Govt. National Test House, ERDA, CPRI or any other NABL

accredited laboratory is required to be submitted. The above type test certificate should not be more

than five years old on the date of opening of the tender. The supplier shall confirm that the material shall

be supplied exactly of the design for which type tests have been conducted.

40.8 INSPECTION:

All the tests and inspection may be conducted at the place of manufacturer unless otherwise

specifically agreed upon by the manufacturer and purchaser at the time of purchase. In case of

inspection at works, the manufacturer shall offer all reasonable facilities to the purchaser without

charges to satisfy him that the material is being furnished in accordance with the specification. In order

to ensure that quality of raw materials used during manufacturing of PVC Cables is as per requirement

of IS:694/1990, the inspecting officer shall check quality of raw material, obtain necessary invoices in

proof that raw materials used are of desired quality.

In addition to above, on receipt of Cables at consignemt, the Employer has the right to have

any or all type/acceptance test carried out through an independent NABL accredited lab like ERDA,

CPRI etc. to ascertain the quality of supply. In case the material fails to pass the test as per

specification, the entire lot shall be rejected and the testing charges along with the other charges which

may likely to be incurred for arranging the testing through independent lab shall be recovered from the

supplier. In addition to this, action as deemed fit, may be taken against the supplier.



41 . TECHNICAL SPECIFICATION ‘ISI’ MARKED PVC INSULATED PVC SHEATHED

ARMOURED ALUMINUM CABLE 2.5 SQ. MM.

41.1 SCOPE :-

This specification covers design, manufacturing, testing and delivery to sites located in M.P. of ISI

marked 1100 Volt grade, weather proof armoured solid alluminium conductor PVC insulated, PVC

sheathed, twin core 2.5 sq. mm cable.

41.2 APPLICABLE STANDARDS:-

All the Cables shall conform to the requirements of following standards with latest amendments, if

any:-

(vi) IS:1554 (Part-I)/1988. - PVC insulated (Heavy Duty) Electric Cables for working voltage up to and including 1100 Volts.

(vii) IS:8130-1984 - Specification for conductor for insulated electric cables. (viii) IS:5831-1984 - Specification for PVC insulation and sheath of electric

cables. (ix) IS:10810-1984 - Methods for test for cables. (x) IS:3961(Part-II) 1967 - Recommended current ratings for PVC insulated and

PVC sheathed heavy duty cables. (xi) IS:4905-1968 - Methods for random sampling. (xii) IS:10418-1972 - Wooden drum for electric cables. (xiii) IS:3975-1979 - Specification for mild steel wires, strips and tape for

armouring of cable.

41.3 GENERAL TECHNICAL REQUIREMENT:-

41.3.1 CONDUCTOR: -

Aluminum conductor used in cables shall comply to the requirement of IS:8130-1984 with latest

amendments and shall be in accordance with clauses of relevant ISS of cables with latest

amendments.

41.3.2 PVC INSULATION: -

PVC insulation used shall comply to requirement of IS: 5831-1984 with latest amendments. PVC

insulation shall be suitable for continuous conductor temperature of 70ºC under normal operation

and 160º C under short circuit conditions. Insulation shall be of ‘Type A’ PVC compound. The

insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be

possible to remove it without damage. The average thickness of insulation shall not be less than

nominal value (ti) specified in relevant ISS. The smallest of the measured values of thickness of

insulation shall not fall below the nominal value (ti) by more than 0.1 mm + 0.1 ti.

41.3.3 FILLER AND INNER SHEATH:-

The filler and the inner sheath shall be of unvulcanised rubber or thermoplastic material or proofed

tape. Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for

insulation and outer sheath. The material shall be chosen to be compatible with temperature ratings

of the cable and shall have no deleterious effect on any other component of the cable.

The laid-up cores shall be provided with inner sheath applied either by extrusion or wrapping. It

shall be ensured that the shape is as circular as possible. The inner sheath shall be so applied that

it fits closely on the laid up cores and it shall be possible to remove it without damage to the

insulation. The thickness of inner sheath shall be as in Table-4 of IS:1554 (Part-I) 1988.

41.3.4 ARMOURING:-



The galvanized steel strip/wire, used for armouring shall comply with the requirement of IS:3975-

1979 with latest amendment. Armouring shall be applied over the inner sheath. The D.C.

resistance of galvanized steel strips armour shall be measured and the result when corrected at

20° C shall comply with approximate value given in Table-6 of IS: 1554 (Part-I)/1988.

The armour strips shall be applied as closely as practicable. A binder tape should be provided on

the armour. Type of armour, its dimension, procedure for its laying and joints shall comply with the

requirement of Clause-13.2, 13.3, 13.1.3 & 13.4. respectively of IS:1554 (Pt-I)/1988.

41.3.5 OUTER SHEATH:-

The outer sheath shall be of type ST1 PVC Compound conforming to the requirements of IS:5831-

1984. The outer sheath shall be applied by extrusion over the armouring and shall be so applied

that it fits closely over armouring. It shall be possible to remove it without damage to inner sheath.

The colour of outer sheath shall be black. The minimum thickness of outer sheath shall not fall

below the nominal value (ts) specified in Table-7 of IS: 1554 (Pt-I)/1988 by more than 0.2 mm ± 0.2

ts.

In case of unarmoured cable, the bidders have also option to offer single sheath. In such a case the

thickness of extruded sheath shall not be less than the sum of the inner sheath thickness specified

in table-4 and the nominal outer sheath thickness specified in column 3 of table-7 of IS:1554. The

smallest of the measured value shall not be less than the sum of the inner sheath thickness

specified in table-4 and the minimum value of outer sheath thickness specified in col.4 of table-7 of

IS:1554.

41.3.6 CORE IDENTIFICATION:- The core shall be identified in accordance with Clause-10 of

IS:1554 (Part-I) 1988.

41.4 IDENTIFICATION, PACKING & MARKING:

41.4.1 Manufacturer’s Identification:- As per Clause-17.1 of IS:1554 (Part-I) following marking shall

be embossed over outer sheath at every 3 mtrs.

(a) Cable size and Voltage Grade.

(b) Name of Manufacturer and Word MPPKVVCL.

The embossing shall be increasive, automatic in line throughout the length of the cable and shall be

legible and indelible.

41.4.2 Packing & Marking:

The cable shall be wound on a drum (ref.IS:10418-1972) of suitable size and packed. The packing

shall be robust for rough handling that is occasioned during transportation. The ends of the cable

shall be sealed by means of non-hygroscopic sealing material.

The cable should carry the following information stenciled on the drum:- (x) Reference to Indian Standard IS:1554 (Part-I) (xi) Manufacturer’s name, brand name or trade mark (xii) Type of cable and voltage grade (xiii) Number of cores (xiv) Nominal cross-sectional area of the conductor (xv) Cable code (xvi) Colour of cores (xvii) Length of cable on the drum (xviii) Number of lengths on drum (if more than one) (xv) Direction of rotation of drum by means of an arrow (xvi) Approximate gross weight



(xvii) Running end of cable (xviii) Country of Manufacturer (xix) Year of manufacture

41.5 ISI Certification Mark:- The cable (Drum) must bear ‘ISI’ Certification Mark. In this connection,

a certified photo-stat copy of valid ‘ISI’ Marking License rights duly attested must be submitted

along with the inspection offer as documentary evidence. In absence of ‘ISI’ License documents,

the inspection offer may not be considered.

41.6 Standard Length:- The standard length of cable shall be 500 meters ± 5% tolerance.

41.7 TESTS:

Following type tests, acceptance tests and routine tests are to be carried out in accordance with

clause-15 of IS:1554(Part-I)1988 with its latest amendments:-

41.7.1 TYPE TESTS: The following shall constitute type tests:

41.7.2 Acceptance Tests: The following shall constitute acceptance tests:-

a. Tensile test

b. Wrapping test

c. Conductor resistance test

d. Test for thickness of insulation and sheath

e. Tensile strength and elongation at break of insulation and sheath

f. Insulation resistance test

g. High voltage test at room temperature

Tests (Whichever is applicable) For requirement ref. to

For Test method ref. to Part No of

IS:10810 A TEST ON CONDUCTOR

i Tensile Test IS:8130-1984 2 ii Wrapping Test IS:8130-1984 3 iii Conductor Resistance test IS:8130-1984 5 B TEST FOR ARMOURING STRIPS Table -5 and

IS:3975/1979 36 to 42

C TEST FOR THICKNESS OF INSULATION AND SHEATH

Table- 2, 4 & 7 of IS:1554/(Part-I)

6

D PHYSICAL TEST FOR INSULATION AND SHEATH i Tensile Strength and elongation at break IS:5831-1984 7 ii Ageing in Air oven -----do----- 11 iii Shrinkage Test -----do----- 12 Iv Hot deformation -----do----- 15 V Loss of mass in air oven -----do----- 10 vi Heat shock test -----do----- 14 vii Thermal stability -----do-----

E Insulation Resistance Test -----do----- 43 F High Voltage Test

at room temperature Clause 16.2 of IS:1554 (Part-I)

45

Water immersion test Clause 16.3. of IS: 1554 (Part-I)

45

G Flammability Test Clause 16.4 of IS:1554 (Part-I)

53



All the above acceptance tests may be carried out by Emplyers representative as per relevant ISS at the time of material inspection for the purpose of clearing the lot offered by the manufacturer. Acceptance test shall be carried out on cable drum selected at random as per following sampling plan:- No. of drums No. of drums to be Permissible number in the lot taken as sample of defectives Upto 50 2 0 51 to 100 5 0 101 to 300 13 0 301 to 500 20 1 501 and above 32 2

41.7.3. Routine Tests – The following shall constitute routine tests:-

(a) Conductor Resistance test (b) High voltage test at room temperature

The above routine tests shall be conducted by the manufacturer in accordance with relevant ISS and test certificate in proof of this shall be submitted to this office along with each inspection offer. In absence of routine test certificate the inspection offer shall be considered as fake and all complication arising out of this shall be to the supplier’s account.

41.8 THER IMPORTANT TECHNICAL REQUIREMENT: Cables shall be designed to withstand mechanical electrical and thermal stress developed under steady state and transient operating conditions.

41.9 TYPE TEST CERTIFICATE: The bidders are advised to submit the certified photocopy of Type Test Certificate along with the tender in respect of the type tests indicated in Clause 4.1 from NABL accredited lab like National Test House, ERDA, CPRI etc. for each size of quoted cables. In absence of Type Test Certificate for all the type tests, the offer is liable for rejection. The bidders shall confirm that they will supply the material exactly for the design for which type tests have been conducted. The above type test certificates should not be more than three years old on the date of opening of tender.

41.10 INSPECTION: All the tests and inspection may be conducted at the place of manufacturer unless otherwise specifically agreed upon by the manufacturer and purchaser at the time of purchase. In case of inspection at works, the manufacturer shall offer all reasonable facilities to the purchaser, without charges to satisfy him that the material is being manufactured in accordance with the specification. In order to ensure that quality of raw materials used during manufacturing of control Cable is as per requirement of IS:1554 (Pt-I)/1988, the inspecting officer shall check quality of raw material, obtain necessary invoices in proof that raw materials used are of desired quality. In addition to above, on receipt of Cables at consignment, the Employerer has the right to have any or all type/acceptance test carried out through an independent NABL accredited lab like ERDA, CPRI etc. to ascertain the quality of supply. In case the material fails to pass the test as per specification, the entire lot shall be rejected and the testing charges along with the other charges which may likely to be incurred for arranging the testing through independent agency shall be recovered from the supplier. In addition to this, action as deemed fit, may be taken against the supplier.



GUARANTEED TECHNICAL PARTICULARS OF ‘ISI’ MARKED PVC INSULATED (HEAVY DUTY)

PVC SHEATHED

UNARMOURED CABLE (To be kept in part-II Commercial/ Technical Bid)

The following information should be furnished for the quoted size of P.V.C. cable:- 1. Name of Manufacturer & Address

2. Whether your product conforms to relevant ISS

3. Relevant ISS No. & Validity

4. GUARANTEED TECHNICAL PARTICULARS:

i) Size of cable 4 core 6 mm2

ii) Brand name, if any.

iii) Rated Voltage

iv) Continuous current rating when laid in air at an ambient temperature :-

a. Current in Amps

b. Ambient temp.°C

c. Conductor temp.°C

v) Short Circuit Current :

a. Short Circuit current(KA)

b. Duration of S/C

c. Conductor temperature allowed for the short circuit duty ° C

vi) Conductor :

a. Grade of Aluminum

b. Nominal Cross Sectional area (Sq.mm.)

c. Conductor resistance per Km at 20°C

d. No. of wires in each conductor

e. Diameter of each wire

f. Source of receipt (Supplier’s Name)

vii) Insulation :

a. Type of insulation

b. Source of receipt (Supplier’s Name)

c. Nominal thickness (mm)

d. Minimum thickness (mm)

e. Colour scheme for identification of cores.

viii) Sheath :

a. Type of PVC Compound

b. Source of receipt (Supplier’s Name)

c. Extruded or wrapped

d. Nominal thickness (mm)

e. Minimum thickness(mm)

ix) Over all dimension of cable

x) Insulation resistance constant per km at

a. 27° C

b. 70° C

xi) Volume resistivity OhmCm at

a. 27° C

b. 70° C

xii) High Voltage Test

a. Voltage applied (KV)

b. Duration (Min.)

xiii) Standard length (Mtr.)

ix) Net weight of cable per coil of 100 mtr. (approx)

SIGNATURE OF TENDERER NAME: DESIGNATION:



GUARANTEED TECHNICAL PARTICULARS OF ‘ISI’ MARKED PVC INSULATED (HEAVY DUTY)

PVC SHEATHED

ARMOURED CABLE

SN. Particulars 2C x 2.5mm2 2C x 4mm2 4C x 10mm2 1 Name of Manufacturers

2 Standard applicable 3 Whether material offered is having ISI mark. Give ISI

marking no. & its validity period

4 Rated Voltage

5 Suitable for earthed or unearthed system 6 Continuous current rating when laid in air at an ambient

temp. 400C and for maximum conductor temperature 700C.

7 Current carrying capacity

a Short Circuit Amps (rms)

b Duration of short circuit

c Conductor temperature allowed for Short Circuit

8 Conductor details

a Material

b Nominal cross section area

c Conductor resistance/Km at 200C

d Source of Supply

9 Insulation details

a Composition and type

b Thickness

c Tolerance in thickness

d Received from (Supplier’s Name)

10 Colour scheme for identification

11 Inner sheath details

a Material

b Extruded/Wrapped, please confirm

c Calculated diameter over laid up cores

d Thickness

f Received from (Supplier’s Name)

12 Armour

a Type of armour

b Nominal diameter over the inner sheath

c Nominal thickness of steel strip/dia. of wire

d Received from (Supplier’s Name)

13 Outer sheath details

a Material

b Extruded, please confirm

c Calculated diameter under the sheath d Thickness f Tolerance on thickness

g Received from (Supplier’s Name)



14 Overall diameter of cable over the outer sheath

15 Volume resistively at 270C and 700C

16 Conductor temperature corresponding to maximum continuous current

17 Test voltage

a High Voltage test

b Water immersion test voltage 18 Recommended minimum installation radius

19 Cable Drum

a Dimensions of the drum

b Approximate weight of Drum

c Maximum length per drum 20 Net weight of cable (Kg/Km)



42.0 TECHNICAL SPECIFICATION FOR STEEL SUPPORTS

1 SCOPE:-

1.1 This specification calls for manufacture, stage testing, inspection and testing before dispatch, packing and

delivery of following Steel sections in M.P. Madhya Kshetra Vidyut Vitaran Co. Ltd., Bhopal:-

S.

No.

Particulars of Item Qty.Reqd.

(in MT)

1 H-Beam 152x152mm

9 m 100 MT

11 m 800 MT

13 M 350 MT

1250

2 RS Joist:

(i) 175x85 mm

125x70 mm

345

105

1.2 The materials shall conform, in all respect, to the high standard of design and workmanship and shall be

capable of performing duties specified herein. Materials offered shall be complete in all respect.

2 STANDARDS:

2.1 Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and

supports conforming to any other international specifications which shall be equivalent or better than IS, the

same is also acceptable.

Sl

Standard No Title

1 IRS T-12

IRS T-18

Specification for Rail Pole – IU (Industrial Use) Grade (R 52) High conductivity rail 52

Kg per Metre.

2 IS:2062 Grade-A Quality Specification for R.S. Joists, M.S. Channels, M.S. Angles & M.S. Flats.

3 IS:2062 Chemical and physical composition of material

4 IS:1852 Rolling and cutting tolerances for Hot rolled steel products.

2.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS:

In the paragraph 2.1 above, relevant Indian standards specification have been mentioned. However, the

material meeting any other authoritative international standards, which ensures equal or better quality than

the standards, mentioned shall also be acceptable. Material for which Indian Standards are not available,

the relevant British standards and IEC recommendations will be applicable. Please attach photocopy of all

such standards according to which the materials have been offered.

3.0 SERVICE CONDITIONS:



3.1 CLIMATIC CONDITIONS:-

The Steel Sections to be supplied against this specification shall be suitable for satisfactory continuous

operation under the following tropical conditions:-

1 Location At various substations in the State of

Madhya Pradesh

2 Max. ambient air temperature 520C

3 Min. ambient air temperature -50C

4 Max. daily average ambient air temperature 400C

5 Max. yearly weighted average temperature 320C

6 Max. Relative Humidity 95% (Sometimes approaches

saturation point)

7 Max. altitude above mean sea level 1000 Meters

8 Average Annual rainfall 125 cm

9 Max wind pressure 150 Kg/sq. meter

10 Isoceraunic level (Average Number

of thunderstorm days per year) 50

11 Seismic level (Horizontal acceleration) 0.3g

4.1 LENGTH:-

The materials to be supplied shall be in the following lengths:-

(i) H-Beam 9 mtrs, 11 mtrs & 13 mtrs each in specified

quantities only

Please ensure that

material supplied

in different lengths

is as per specified

quantities of those

lengths only.

(ii) R.S. Joists 9 metres to 11 metres

Any tolerance on negative or positive side shall not be accepted.

4.2 WEIGHMENT:-

The weightment of Steel Section shall be witnessed by the consignee at the time of taking delivery. The

weight recorded in the material receipt certificate issued by the consignees shall be final.

5. CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES OF IU RAIL POLES [IRS T-12, IRS T-18

High Conductivity (only R-52) IU Grade]

CHEMICAL COMPOSITION: -



C SI

(Max.)

S

(Max.)

P

(Max.)

Mn

(Max.)

0.60 0.10 0.055 0.055 0.80

0.85 0.50 0.055 0.055 1.40

MECHANICAL PROPERTIES:-

Tensile Strength Mpa Percentage Elongation

840 Min 10.00 Min

840 Min 10.00 Min

CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF R.S. JOISTS, CONFORMING TO IS: 2062/84

CHEMICAL COMPOSITION

CHEMICAL COMPOSITION FOR Fe 410 WA GRADE

1 C -- 0.23% MAX.

2 Mn -- 1.5% MAX.

3 S -- 0.050% MAX.

4 P -- 0.050% MAX.

5 SI -- 0.40% MAX.

6 CE

(Carbon Equivalent)

-- 0.42% MAX.

MECHANICAL PROPERTIES

1. Tensile strength (min.) – 42 Kgf/mm2 or 410 N/mm2

2. Yield stress Min. for thickness/diameter

< 20 mm - 26 kgf/mm2 OR 250 N/mm2

20–40mm - 24 kgf/mm2 OR 240 N/mm2

> 40 mm

- 23 kgf/mm2 OR 230 N/mm2

3. Elongation %(min.) - 23%

Bend test (internal Dia) - Min-3 t

(t – is the thickness of the material)

6. TOLERANCE IN QUANTITY:-

Variation in ordered quantity for any destination and over-all ordered quantity shall be only to the extent of



± 2%. Rolling and weight tolerances shall be as per latest version of IS:1852 or to any equivalent

International Standard. Any claim of quantity supplied in excess of above limits shall not be admitted.

7. MARKING:-

It is desirable that the Bidder should put his identification marks on the finished materials. The mark shall

be in ‘legible English letters’ given with marking dies of minimum 18 mm size.

8. INSPECTION AND TEST CERTIFICATE:-

The materials to be supplied will be subject to inspection and approval by the representative of Company in

case of Re-rollers. The firm is required to offer the finished material for inspection well in advance to this

office. The finished materials shall be delivered to our consignees only after the same are inspected and

approved for delivery by your Inspecting Officer/this office. It is to be noted that you are required to deliver

the inspected materials approved for delivery ‘WITHIN 21 DAYS’ time from the date of dispatch clearance

given from this office or by inspecting officer whichever is earlier, failing which the penalty clause as

mentioned above shall be applicable on such supplies which are made after one month period counted

from the date of dispatch clearance given by this office/Inspecting Officer.

The BILLETS/INGOTS from which materials shall be re-rolled and supplied to us shall be of tested quality

as per IS: 2830/6914 (Latest revision) respectively and shall be arranged from their own source. The

Chemical Composition and Physical properties of the finished materials shall be as per relevant

specification indicated in Schedule-I enclosed.

The materials shall be tested in ISI approved Laboratory of the tenderer having all facilities available for

conducting all the tests as prescribed in relevant ISS. The materials shall be tested either in their ISI

approved Laboratory or in any Govt. approved laboratory. The testing charges whatsoever shall be to the

tenderer’s account. It may be mentioned here that the Company reserves the right to get the materials

tested at its discretion or at any recognised Laboratory at the cost of the tenderer.

The tenderers are required to specifically indicate that:-

(i) They hold valid ISI License against respective ISS.

(ii) That the materials offered against this tender are bearing ISI certification marks.

The tenderers are required to submit a copy of the valid ISI License clearly indicating size and range of roll-

able product against respective ISS along with their offer. It is to be noted that in case any of the two

conditions as mentioned above i.e. (i) holding of valid ISI License and (ii) finished materials bearing ISI

certification marks, are not fulfilled, the tender shall not be accepted / considered. ATTESTED

PHOTOSTAT COPIES OF THESE LISENSES ISSUED IN FAVOUR OF THE TENDERER SHOULD BE

SUBMITTED ALONGWITH THE TENDER.

9. TRANSPORTATION AND HANDLING CHARGES:-

The road transportation charges including loading of materials into TRUCK/TRAILOR at tenderers works

and transportation from the works to the specified destinations shall be indicated in the break-up of F.O.R.

destination prices mentioned in Schedule-III. The transportation charges are on ‘FIRM’ price basis and,



therefore, no price variation on transportation charges, on any account whatsoever, shall be permitted. The

responsibility of transportation of material up to various destinations shall rest on the tenderer. However,

please note that no transshipment of despatched material shall be allowed. The unloading of material from

TRUCK/TRAILOR at our Stores/Workshop will be arranged by the consignees.

10. GUARANTEE PERIOD:-

If during the course of 18 months subsequent to the date of receipt of consignment or 12 months

from the date of commissioning, whichever is earlier, any of the goods are found to be defective in

material or workmanship or develop defects during service, they will have to be replaced / repaired by

the suppliers free of all charges. All necessary arrangements on this account will be made by the

suppliers.

Following conditions shall also be applicable against the contract:-

(i) In case any defect in the materials is found within guarantee period, the same shall be replaced by the

tenderer, on free of cost basis. The replacement will have to be organized expeditiously and preferably

within one month’s time.

(ii) In case, for the purpose of arranging replacement, the defective/failed/rejected material is required to be

despatched to tenderer works, all charges towards transportation/insurance/ packing etc. shall be borne by

the tenderer for to and fro despatches.

(iii) In case the material develops any defect either in workmanship or in quality within guarantee period after

installation at site, for the purpose of replacement, the same will be dismantled and taken out by us. In

such case, actual cost of dismantling and replacement of the material shall also be recoverable from the

tenderer.

(iv) In case it is observed that replacement of material is not being provided within reasonable period or proper

response is not being received from the tenderer, then apart from operating clause of penalty (which

provides for imposition of penalty / liquidated damages, risk purchase at tenderer’s cost and cancellation of

contract) the Board may also take suitable penal action against the tenderer, which may interalia include

black listing for further business from the Board i.e. debarring to firm for 3 to 5 years.

11. IMPORTANT NOTE:-

(i) THE TENDERER SHOULD QUOTE THE RATES FOR THOSE ITEMS WHICH THEY ARE ROLLING.

THE QUOTED RATES SHOULD BE APPLICABLE FOR PART QUANTITITES ALSO (IT COULD BE SO

ORDERED).

(ii) THEY SHOULD ALSO INDICATE THE SOURCE OF SUPPLY FOR THE ITEM WHICH THEY ARE NOT

ROLLING AND ARE ROLLED BY THEIR CONVERSION AGENT.

(iii) THE TENDERER SHOULD QUOTE THE RATES IN THE PRESCRIBED PRICE SCHEDULE-III ONLY,

OTHERWISE THE OFFER IS LIABLE FOR REJECTION. THE BIFURCATION OF EACH ELEMENT AS

ASKED FOR MAY ALSO BE INDICATED. PRICE SCHEDULE IS TO BE POSTED ONLINE ONLY.

(iv) THE COMPANY RESERVES THE RIGHT TO ACCEPT OR REJECT ANY OR ALL THE OFFERS IN

PART OF FULL WITHOUT ASSIGNING ANY REASONS WHATSOEVER AND ALSO TO INCREASE /

REDUCE / DELETE THE QUANTITY OF THE MATERIAL.

(v) The technical particulars as asked in Schedule-II should be filled in carefully. The offers wherein any

deviations/short-comings are found in G.T.P. are liable for rejection.

(vi) The quantity of various items as mentioned in Schedule-I is subject to change, therefore, in case, any

rebate is offered for quantity on order, the same shall specifically be mentioned.



43.0 TECHNICAL SPECIFICATION OF LT TRANSFORMER PROTECTION

CUM DISTRIBUTION SYSTEM (FOR 100 KVA RATINGS)

1. SCOPE:

This specification covers the design, manufacture, testing before dispatch, supply and delivery of 100 KVA

L.T. Transformer Protection cum Distribution System.

2. CLIMATIC CONDITIONS:

The climatic conditions at site under which the equipment shall operate satisfactorily are as under :

1 Location In the State of Madhya Pradesh, India

2 Maximum ambient air temp. 50 °C

3 Minimum Ambient Air Temperature (-) 1 °C

4 Average Daily Ambient Air Temperature 32 °C

5 Maximum relative humidity 90% Sometimes approached to saturation.

6 Average rainfall per annum(mm) Not more than 1000 mm (Average 200 to 600 mm)

7 Maximum Altitude above mean sea level (meters) 815

8 Isoceranic level (Day/annum) 120/50

9 Maximum Wind Pressure (Kg/Sq. meters) 45

10 Seismic level (Horizontal acceleration) 0.1 g

The system generally be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth

unless otherwise specified.

3. GENERAL REQUIREMENTS :

SL. No. Particulars

i) SCOPE Manufacture, Testing & Supply of L.T. Transformer Distribution System

ii) SYSTEM 415 Volts, AC 3 Phase 4 Wire 50 C/S with effectively grounded neutral system

4. SYSTEM DETAILS:

LT Transformer Distribution System mainly consists of following main items detailed below :

4.1 One chamber to house incoming, one Isolator double make double break type 250 A , as per

IS/IEC60947-2:2003, Four Pole MCCB double make double break type 200 Amp. - 36 KA as per

IS/IEC60947-2:2003 with Bus bar connection system. This chamber may be called CHAMBER NO. 1 or

Protection Chamber.

4.3 Other chamber to house 6 numbers of Single Pole MCCB's 100 Amp. 36 KA double make/ double break

capacity with outgoing Bus bar connections and neutral bus bar. This chamber may be called CHAMBER

NO. 2 or Distribution Chamber. The MCCBs shall be confirming to IS/IEC60947-2:2003

4.4 Supporting MS Frame work for the above Chambers Nos. 1 to 2.

4.5 Spacers for connecting the chambers.

4.6 External Earthing Plate for earthing of connections.

4.7 Cable Clamps for incoming & outgoing cables.



Further details of the above are :

4.1 CHAMBER NO. 1 : PROTECTION CHAMBER :

4.1.1 Construction Features : The box shall be adequately protected against rust, dust, water and

corrosion both from inside and outside. The box shall be so constructed as to have roof tapering back side

for easy flow of rain water.

4.2.3 Dimensions : Dimensions of the Chamber No. 2 or Protection Chamber will be as per drawing

4.2.4 Thickness : Base : 3.0 mm + 0.25 mm

Cover : 3.0 mm + 0.25 mm

4.2.5 MCCB : Four Pole MCCB 200 Amp. - 36 KA

A four pole MCCB of rating 150 Amp. should be provided in this chamber for protection. The following

make of MCCB shall be acceptable. : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER /

SPACEAGE Hyundai or any other make which conforms to the specifications.

Detailed technical parameters of Four Pole MCCB 200 Amp. MCCB - 36 KA as per Schedule - A.

Four Pole Isolator 250 Amp

A four pole Isolator of rating 150 Amp. should be provided in this chamber for protection. The following

make of Isolator shall be acceptable. : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER /


Detailed technical parameters of Four Pole Isolator 250 Amp. Isolator - as per Schedule-c.

4.2.6 Mounting Arrangement of Four Pole MCCB 200 Amp. - 36 KA : M.S. 2.0 mm + 0.2 mm thick mounting

bracket should be provided with proper mounting holes and clamps to accommodate four pole MCCB 200

Amp. - 36 KA. The plate should be zinc plated and yellow passivative.

4.2.8 Arrangement of inter connection of Bus bar :

Inter connection of bus bar should be done, and proper gap should be maintained between all phase and

neutrals. DMC moulded support should be used to provide rigid support and insulation.

Holes for incoming Cables : For incoming cable 4 Nos. hole with insulated plastic glands on the base of

the chamber shall be provided and gland plates with suitable holes for incoming cable shall be provided.

4.1.9 Gland Plate : M.S. 2.0 mm + 0.2 mm thick zinc plated yellow passivated gland plate should be provided at

the incoming side of the box i.e. at the bottom of the box.

4.2.9 Hinges : Two Nos. of hinges should be provided to join base with cover from one side in such a manner

that no screw or rivets will be visible from outside. The cover should be closed from top to bottom with pull

push facility separately for box no. 1 and box 2 with moving lever arrangement each side of box as per

drawing

4.2.10 Rubber Gasket : The coller in the Base of Chamber shall be provided with good quality rubber 'O' ring. The

design of lining shall be such that it provides proper sealing between the cover and base of chamber to

avoid penetration of dust and ingress of water. This may be achieved by providing an U shape groove in

the outer flange of the base and all around projection provided on the cover periphery, which keeps the 'O'



ring pressed and also to provide an outside caller to cover the groove. This will avoid ingress water, dust

etc.

4.2.11 Ventilation : Ventilation plugs (Elbow type) has to be provided having built in mesh to protect against

entry of insects and lizards. These vents shall be fixed / tightened from inside facing down as not to

allow water inside. These plugs will provide breathing inside the chamber. The IP rating of individual

chambers should be IP 55 but the test has to be done on enclosures in which the holes have been

blocked.

4.2.12 Padlock Arrangement : Pad lock arrangement should be provided to lock / seal the base and cover.

4.2.13 Bus Bar : Size of Bus Bar should have cross sectional area of 50 x4 mm + 2.5% made of EC Grade

copper Covered with Phase identification PVC Colour Coding Sleeves.

4.2.14 Sealing Arrangement : 2 Nos. of sealing bolts & nuts should be provided to seal the box and also to

close the cover on base.

4.3 CHAMBER NO. 2 : Six (6) Nos. 100 Amp. 36 KA Single Pole MCCBs, incoming and outgoing Bus

bar connections and neutral bus bar.

4.3.1 Construction Features : The base and cover should be made by means of MS sheet of IS: 2147/1962 or

to equivalent any international standard.

The box shall be adequately protected against rust, dust, water and corrosion both from inside and

outside. .

4.3.3 Dimensions : Dimensions of the Chamber No. 2 or Distribution System will be as per drawing

4.3.4 Thickness : Base : 3.0 mm + 0.25 mm

Cover : 3.0 mm + 0.25 mm

4.3.5 Mounting arrangement of Bus bar : D.M.C. Moulded Bus bar holding supports should be mounted in the

chamber so that all the bus bars can be interconnected through Chamber No. 1with Chamber No. 2 with

proper gap and insulation. The cross sectional area of Bus bars is to be 50 x4 mm.

4.3.6 MCCB : Single Pole MCCB 100 Amp. - 36 KA

Six (6) numbers single pole MCCBs of rating 100 Amp. should be provided in this chamber. The following

make of MCCB shall be acceptable : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER/


Detailed technical parameters of Single Pole MCCB 100 Amp. - 36 KA as per Schedule - B.

4.3.7 Mounting Arrangement of Single Pole MCCB 100 Amp. - 36 KA : M.S. 2.0 mm + 0.25 mm thick

mounting bracket should be provided with proper mounting holes and clamps to accommodate 6 numbers

of single pole 100 Amp. MCCBs- 36 KA. The plate should be zinc plated and yellow passivative.

4.3.9 Neutral Bar : A pre drill and tapped neutral bar should be provided of cross sectional area 150 Sq. mm +

2.5% to take the neutral for outgoing connections.

4.3.10 Holes for incoming and outgoing : For outgoing connections 9 number of holes with Engineering Plastic

glands will be provided at the bottom of the chamber. A gland plate of M.S. 2.0 mm thick zinc plated

yellow passivated should be provided.

4.3.11 Hinges : Two Nos. of hinges should be provided to join base with cover from one side in such a manner

that no screw or rivets will be visible from outside. The cover should be closed from top to bottom with pull

push facility separately for box no. 1 and box 2 with moving lever arrangement each side of box as per

drawing

4.3.12 Rubber Gasket : The collar of the body shall be provided with good quality rubber 'O' ring. The design of

lining shall be such that it provides proper sealing between the cover and base of chamber to avoid

penetration of dust and ingress of water. This may be achieved by providing an U shape groove in the



outer flange of the base and all around projection provided on the cover periphery, which keeps the 'O'

ring pressed and also to provide an outside caller to cover the groove. This will avoid ingress water, dust

etc.

4.3.13 Ventilation : Ventilation plugs (Elbow type) has to be provided having built in mesh to protect against

entry of insects and lizards. These vents shall be fixed / tightened from inside facing down as not to allow

water inside. These plugs will provide breathing inside the chamber. The IP rating of individual chambers

should be IP 55 but the test has to be done on enclosures in which the holes have been blocked.

4.3.14 Padlock Arrangement: Pad lock arrangement should be provided to lock / seal the base and cover.

4.3.15 Bus Bar : Size of main Bus Bar should be 50X4 mm + 2.5% and main bus bar should be connected to the

100 Amp. MCCB by means of copper strip of cross section of 45 sq. mm + 2.5% made of EC Grade

copper.

4.3.16 Sealing Arrangement : 2 Nos. of sealing bolts & nuts should be provided to seal the box and also to close

the cover on base.

4.4 Supporting MS Frame for Chamber Nos. 1 to 2 :

MS Angle 30x30x5 mm + 2.5% with 6 mm flats in between should be used to make the back frame of the

entire system. It should be made in such a manner that entire back side edge / corner should be held by

this frame rigidly. Each box is to be fixed at min. 4 places at Base.

MS Frame should be Hot Dip Galvanised material.

4.5 Spacers for connecting the Chambers :

For joining the Chamber No. 1 with Chamber No. 1; with Chamber No. 2 especially designed spacers are

to be used with O ring all around on both sides to avoid ingress of water and dust. This spacer is

sandwiched between 2 chambers in a fashion, so it fit into the groove provided on the sides of the

chambers and duly bolted with each other. The spacers shall have openings for bus bars to pass through

the joints and spacers.

4.6 External Earthing Plate for Earthing :

M.S. 2.0 mm + 2.5% thick hot dip galvanised plate with 6 Nos. of M8x40 Nut, bolts and washer should be

fitted on the bottom of chamber for providing earthing for outgoing connections.

4.7 Cable Clamps for incoming Cables :

Sufficient numbers of MS U Shaped bend clamps with bots and nuts should be fitted on metal frame to

hold and support the incoming cables firmly.

4.8 Cable Clamps for outgoing Cables :

Sufficient numbers of MS U Shaped bend clamps with bots and nuts should be fitted on metal frame to

hold and support the outgoing cables firmly.

Note :

01. Tolerances for current carrying parts should be :

a) Thickness : + 2.5%

b) Length : + 2.5%

02. Tolerances for metal parts should be : a) Thickness : + 2.5%

b) Length : + 2.5%



SCHEDULE - A

TECHNICAL SPECIFICATION FOR FOUR POLE MCCB 200 Amp - 36 KA

FOR 100 KVA TRANSFORMER PROTECTION CUM DISTRIBUTION SYSTEM

Application Outdoor (enclosed).

Utilization category ‘A’ (IS: 13947-1993) as amended up to date

Type Thermal-Magnetic trip free mechanism.

Number of poles Four

Peak ambient temperature 50 °C.

Rated insulation level 600 V.

Rated operational voltage 433 V.

Continuous current rating 200A

Ultimate Short Circuit Breaking capacity (ICU) 36 KA

Rated service Short Circuit Breaking capacity (ICS) 36 KA

Application Standard IS: 13947 Part-2 (latest) - 1993

Time current characteristics To co-ordinate with HV fuse.

Durability (C-O Cycles)

a) mechanical

b) electrical

8500

1500

*******



SCHEDULE - B

TECHNICAL SPECIFICATION FOR MCCB - 100A

FOR 63 KVA TRANSFORMER PROTECTION CUM DISTRIBUTION SYSTEM


Utilization category ‘A’ (IS: 13947-1993) as amended up to

date


Number of poles Single





Ultimate Short Circuit Breaking capacity (ICU) 36 KA

Rated service Short Circuit Breaking capacity (ICS) 36 KA

Application Standard IS: 13947 Part-2 (latest) - 1993

Time current characteristics To co-ordinate with HV fuse.

Durability (C-O Cycles)

a) mechanical

b) electrical

8500

1500

*********



SCHEDULE - C

TECHNICAL SPECIFICATION FOR Four Pole Isolator - 250A

FOR 100 KVA TRANSFORMER DISTRIBUTION SYSTEM


Utilization category ‘AC’ 23 A asIS/IEC 60947-2:2003 as

amended upto date


Number of poles Four





Rated service Short Circuit making capacity (ICM) 30

Application Standard IS: 60947-2:2003

Short time withstand current (A rms) ICW

1 Sec-9000A

3 Sec-5000A

20 Sec-2300A

30 Sec-1800A



GTP of DISTRIBUTION CUM PROTECTION BOX FOR 100 KVA 11/.4KV TRANSFORMER

N Particulars Specification Details Guaranteed Valu

e

I SYSTEM DETAILS

a) KVA 100 KVA

b) Voltage 415 V

c) Frequency 50 c/s

d) Full load current 140 A

e) No. of circuit on outgoing side

2 Nos. per Phase

I ISOLATOR a) Triple Pole 250 Amps. of any

approved brand on incoming side.

b) Whether the Isolator meets

the technical requirement of

specification.

Ia) Cross Section of the terminal

strip of Isolator

b) Length of the terminals of the Isolator

c) Material of strip

50 x 4sq.mm.

80mm on incoming and 60mm

on outgoing side.

Tinned copper

I DETAILS OF MCCB

i) Make of MCCB

ii) No. of ckts.

iii) Nominal current iv) No. of Poles

2 Nos./Phase

130 Amps.

Single Pole

8Whether the MCCB is of approved make

(Then the details of guaranteed technical particulars need not be

enclosed)



N Particulars Specification Details Guaranteed

Value

9 f terminal strip 50 x 4 sq.mm.

1Length of incoming side and outgoing

side

Length of incoming side is 60

mm & outgoing side is

80 mm

1Material of strip Tinned copper

V BUS BAR DETAILS

1. Material

2. Size of the main bus bar

3. PVC Insulation of standard

colour code is to be provided on the bus bar

4. Minimum clearance of the bus bar Top side, between the bus

bar

Tinned copper

50X4 sq.mm.

Weather coloured sleeve

insulation has been

provided on the bus

bar & at joints M-seal compound has been

painted.

As per drawing

V ENCLOSURES

1 Size As per drawing

2 Material M.S. Sheet

3 Thickness 3 mm of all sides

4 Arrangement for Pad Lock Arrangement for pad lock as

per Drawing

5 Auto Lock with push pull facility To be provided

6 Slopping of the roof Slopping of 5º from the front

to back

7 Colour of the Box Grey

8 Bottom Plate Bottom Plate




Value

9 Thickness Should be made of 3 mm thick

perforated and should

be detachable.

1 Additional Support 3 mm thick plain sheet

1 Knock out holes 3 Nos. with PVC Glands.

One no. suitable 150 sq.mm.

on incoming side and 2 Nos. for outgoing side

of 70 sq.mm. size

1 Air Circulation Both sides Ventilation

1 Bottom Cleats Four Bottom Cleats of 75x40x3 mm thick M.S.

provided

1 Instructions to Lineman in Hindi Provided

To be provided on the back of the door of the box.

1 Hinges Hinges of the door is to be

provided with Brass

tube

1 Danger plate Duly enameled on both sides.

1 Identification plate Identification plate is to be

provided indicating the details as under :-

Name

Rating of Box

Sr. No.

Date of Manufacturing

Order No. & Date

1 Nut & Bolts All nuts & bolts of the current

carrying part should be

made of stainless steel

with washer.

1 Earthing Bolts Earthing bolts to be provided of 50 x 12 mm on each




Value

side with one spring

washer & two plain

washers

2 Neutral Bus Bar 50X4 sq.mm. size or equivalent

neutral bus bar to be provided along with

lugs with steel washer

2 Lugs on Incoming side Bimetallic lugs suitable for 150 sq.mm. 3-1/2 Core on

incoming side & 70 sq.mm. on outgoing

side

2 Cable Holding Clamp Cable holding clamp of 2 mm thick with 4 mm base

strip to be provided

2 Opening of door from top to bottom with moving

lever facility

As Per drawing

V SPECIAL REMARKS

Total Technical Specs PDF

Documents

Transcript of Total Technical Specs PDF